Miller | LE411272 | Owner Manual | Miller MILLERMATIC 350 User manual

Miller MILLERMATIC 350 User manual
OM-1327
213 814G
November 2004
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
with Roughneck 4012 Gun
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Installing Welding Gun/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting Spoolmatic) 15A Or 30A Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Connecting XR Edge, XR-A Gun, Or XR-A Python . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Installing Wire Spool and Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Selecting A Location And Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Selection A Location And Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15. Threading Welding Wire For Roughneck Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16. Threading Welding Wire For XR Edge, XR-A Gun, Or XR-A Python . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. 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 And Pulse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. MIG Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Pulse MIG Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Arc Times And Arc Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 6 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
30
30
30
31
32
34
36
38
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-1327 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-1327 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-1327 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-1327 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-1327 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-1327 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
D
D
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-1327 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-1327 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − 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)
(1.3−17.8
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
Y 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 9
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. 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-B
OM-1327 Page 10
3-5. Installing Welding Gun/Cable Holder
1
2
3
2
Welding Gun/Cable Holder
Wrapper
Slots
Angle holder to insert hook through
bottom slot. Drop holder down so
that hook exits top slot.
3
1
Ref. 803 545-A / Ref. 803 539-A
3-6. 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.
3
1
2
4
Ref. 803 541-A
OM-1327 Page 11
3-7. 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
4
3
Tools Needed:
3/4, 5/8 in
OM-1327 Page 12
803 568-B
3-8. Connecting XR Edge, XR-A Gun, Or XR-A Python
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
Be sure to change drive rolls to the
proper size and type.
1
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-A / Ref. 803 570 -A / Ref. 803 463
OM-1327 Page 13
3-9. 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 14
3-10. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
.
DO NOT use Argon/Mixed gas regulator/flowmeter with CO2 shielding gas. See Parts List for optional
CO2 gas regulator/flowmeter.
Regulator/Flowmeter
for 350P model shown.
1
7
4
2
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.
3
5
Argon Gas Or
Mixed Gas
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on
rear of welding power source.
7
Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
manufacturer’s
recommended
flow rate.
6
Rear Panel
Tools Needed:
1-1/8, 5/8 in
803 542-A
3-11. 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
072573-B
OM-1327 Page 15
3-12. Electrical Service Guide
Single-Phase
Three-Phase
Input Voltage
200
230
460
575
200
230
460
575
Input Amperes At Rated Output
69
61
30
24
34
30
15
12
80
70
35
25
40
35
15
10
100
90
40
35
50
45
20
15
6
8
10
12
10
10
14
14
101
(31)
86
(26)
229
(70)
217
(66)
86
26
114
35
178
54
277
85
8
8
10
12
10
10
14
14
Max Recommended Standard Fuse Or Circuit Breaker Rating
In Amperes
Circuit Breaker 1, Time-Delay 2
Normal Operating
Min Input Conductor Size In AWG
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
3
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
Y Caution: This unit is either a 200/230 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 16
3-13. Selecting A Location And Connecting 3-Phase Input Power
Y Do not move or operate
unit where it could tip.
= GND/PE Earth Ground
7
3
18 in (457 mm)
for airflow
6
4
5
2
1
Rear Panel
Tools Needed:
803 543-B
Y Installation must meet all National and
Local Codes - have only qualified
persons make this installation.
Y Disconnect and lockout/tagout input
power before connecting input
conductors form unit.
Y Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
Y Caution: This unit is either a 200/230
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.
Disconnect
Device
Connections
Input
Power
conductor to disconnect device grounding
terminal first.
1
Rating Label
6
2
Input Power Conductors
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
3
Line Disconnect Device
7
4
Disconnect Device (Supply) Grounding
Terminal
5
Grounding Conductor
Select type and size of overcurrent protection
using Section 3-12 (fused disconnect switch
shown).
Connect green or green/yellow grounding
Disconnect Device Line Terminals
Overcurrent Protection
Close and secure door on line disconnect
device.
OM-1327 Page 17
3-14. Selection A Location And Connecting 1-Phase Input Power
Y Do not move or operate
unit where it could tip.
= GND/PE Earth Ground
8
11
18 in (457 mm)
for airflow
10
9
6
3
4
6
1
2
5
7
Rear Panel
2
Tools Needed:
Ref. 803 543-B
Y Installation must meet all National and
Local Codes - have only qualified
persons make this installation.
Y Disconnect and lockout/tagout input
power before connecting input
conductors form unit.
Y Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
Y Caution: This unit is either a 200/230
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 18
Three Conductor Power Cord Preparation
1
2
3
4
5
6
7
Rating Label
Input Power Conductors
Black And White Input Conductors
Red Input Conductor
Insulation Sleeving
Grounding Conductor
Electrical Tape
Insulate and isolate red conductor as shown.
Disconnect
Device
Connections
8
Input
Line Disconnect Device
Power
9
Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding
conductor (see Item 6) to disconnect device
grounding terminal first.
10 Disconnect Device Line Terminals
Connect input conductors L1 and L2 to
disconnect device line terminals.
11 Overcurrent Protection
Select type and size of overcurrent protection
using Section 3-12 (fused disconnect switch
shown).
Close and secure door on line disconnect
device.
3-15. Threading Welding Wire For Roughneck 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.
8
1
2
3
4
5
Tools Needed:
6
.
Hold wire tightly to
keep it from unraveling.
6 in
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
.
Tighten
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
Push wire thru guides into gun;
continue to hold wire.
Use pressure indicator scale to set a desired drive roll pressure.
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-A / 803 544-A / S-0627-A
OM-1327 Page 19
3-16. Threading Welding Wire For XR Edge, XR-A Gun, Or XR-A Python
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
.
IMPORTANT!
For Aluminum Push−Pull welding.
Thread hub tension nut loosely
Hold wire tightly to
keep 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 3-17 for threading
welding wire through XR guns.
Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A
OM-1327 Page 20
3-17. Threading Welding Wire Through XR Guns
Y Welding wire is electrically live
when gun trigger is used to jog
wire.
.
For XR-A Edge Gun:
Refer to Section 3-16 for instructions 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.
1
Turn On
Welding Power
Source.
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.
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.
.
Cut off wire. Close and latch door.
Y Turn welding power source Off.
Do not exceed midrange setting.
Ref. 802 193-A / 801 556 / Ref. 151 666-C
OM-1327 Page 21
SECTION 4 − OPERATION
4-1. Controls
11
10
1
2
12
3
4
7
5
6
8
1
Pulse Indicator Light
Use button to access Timers, Process and
Wire menus.
.
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
NOTE
9
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 14-32 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.
OM-1327 Page 22
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
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.
NOTE
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 23
4-9. Weld Parameters For MIG And Pulse Mode
Reference
Volts/Wirefeed
23.5/220
OM-1327 Page 24
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 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).
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)
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
OM-1327 Page 25
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 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)
Depress SETUP (6) button again to exit
menus and enter PULSE welding mode.
OM-1327 Page 26
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
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.
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.
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
Spot/Stitch 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.
OM-1327 Page 27
5-4. Arc Times And Arc Starts
.
Accessing the Arc Times and Arc Starts 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.
OM-1327 Page 28
Left display will initially show number of arc
starts.
Rotate right knob (8) and display will
change to show arc hours.
Ref. 213 935-A
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.
5-5. 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, press and hold the
SETUP (1) button, and turn on welding
power source.
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.
OM-1327 Page 29
SECTION 6 − MAINTENANCE &TROUBLESHOOTING
6-1. Routine Maintenance
Y Disconnect power
before maintaining.
.
Maintain more often
during severe conditions.
3 Months
Replace unreadable labels
Repair or replace
cracked weld cable
Clean and tighten weld terminals
Check gun
cable.
6 Months
Blow out or vacuum inside.
OR
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 30
6-3. Changing Drive Roll and Wire Inlet Guide
1
2
.045 Groove
Securing Screw
Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
.035 Groove
3
Anti-Wear Guide
Install guide as shown.
6
Stamped
.035
4
Intermediate Guide
5
Drive Roll
.
Stamped
.045
The drive assembly comes
equipped with factory installed
.035/.045 combination drive
rolls. Be sure that all 4 drive
rolls are installed correctly.
3
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.
6
Tools Needed:
5/64 in
7/16 in
5
1
Drive Roll Securing Nut
Turn nut one click to secure drive
roll.
4
802 520-A
OM-1327 Page 31
6-4. Troubleshooting
Trouble
Remedy
No weld output; wire does not feed.
Be sure line disconnect switch is On (see Section 3-13 or 3-14).
Replace building line fuse or reset circuit breaker if open (see Section 3-13 or 3-14).
Secure gun trigger connections (see Section 3-6).
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 3-13 or 3-14).
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 6-3).
Readjust drive roll pressure (see Section 3-15).
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 3-15).
Change to correct size drive rolls (see Section 6-3).
Rethread welding wire (see Section 3-15).
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 32
Notes
OM-1327 Page 33
6-5. Help Displays
V
A
HELP
V
0
A
HELP
V
A
HELP
V
3
A
HELP
V
HELP
V
5
V
HELP
OM-1327 Page 34
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
11
A
SAVE
A
350P
A
350
A
JOG MODE
.
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 1). Unit will shutdown until internal
temperature drops within operational range.
S
Help 1
Indicates communication lost between
control board PC1 and user interface board.
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 no open circuit voltage detected
when gun trigger is pulled and no arc
detected within 3 seconds. If this display is
shown, 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 Mode
Indicates trigger is pressed, but no arc is
detected. Wire feed speed goes to Jog mode
speed after 3 seconds.
SC-187 212-A
OM-1327 Page 35
SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram
OM-1327 Page 36
212 985-G
OM-1327 Page 37
. Hardware is common and
15
14
SECTION 8 − PARTS LIST
19
20
24
25
26 − Fig 8-4
28
27
1
2
4
3
5
6
7
8 − Fig 8-2
23
22
9
10 − Fig 8-3
21
11 − Fig 8-5
12
18
17
13
16
not available unless listed.
803 545-A
Figure 8-1. Main Assembly
OM-1327 Page 38
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . . 1 . . . . . . . . . . 212829
. . . 2 . . . NEG . 097416
. . . 3 . . . POS . 097421
. . . 4 . . . C6,7 . 213038
. . . 5 . . . HD1 . . 189567
. . . . . . . . . . . . . . . . 183046
. . . 6 . . . . . . . . . . 221326
. . . 7 . . . . . . . . . . 199824
. . . 8 . . . . . . . . . . . Fig 8-2
. . . 9 . . . . . . . . . . 212821
. . . 10 . . . . . . . . . . . Fig 8-3
. . . 11 . . . . . . . . . . +Fig 8-5
. . . 12 . . . . . . . . . . 134464
. . . 13 . . . . . . . . . . 212826
. . . 14 . . . . . . . . . . 217829
. . . 15 . . . . . . . . . . 215061
. . . 16 . . . . . . . . . +212823
. . . 17 . . . . . . . . . . 213939
. . . 18 . . . . . . . . . . 186758
. . . 19 . . . . . . . . . . 602250
. . . 20 . . . . . . . . . . 121614
. . . 21 . . . . . . . . . . 213903
. . . 22 . . . . . . . . . . 212833
. . . 23 . . . . . . . . . . 209870
. . . 24 . . . FM . . 213043
. . . 25 . . . . . . . . . . 212846
. . . 26 . . . . . . . . . . . Fig 8-4
. . . 27 . . . . . . . . . . 212822
. . . 28 . . . . . . . . . . . 151187
. . . . . . . . . . . . . . . . 194755
. . . . . . . . . . . . . . . . 209123
. . . . . . . . . . . . . . . . 210925
. . . . . . . . . . . . . . . . 144108
. . . . . . . . . . . . . . . . 196329
. . . . . . . . . . . . . . . . 130750
. . . . . . . . . . . . . . . . 196318
. . . . . . . . . . . . . . . . 213369
. . . . . . . . . . . . . . . . 213619
. . . . . . . . . . . . . . . . 196318
. . . . . . . . . . . . . . . . 206186
. . . . . . . . . . . . . . . . 206188
. . . . . . . . . . . . . . . . 220524
. . . . . . . . . . . . . . . ♦212492
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
DOOR,ACCESS WIRE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL,PWR OUTPUT BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL,PWR OUTPUT RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSDUCER,CURRENT 400A MODULE SUPPLY V +/− 15V . . . . . . . . . .
CABLE,LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR,CURRENT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING ELECTIC SHOCK AND PINCH POINTS . . . . . . . . . . . . . .
BAFFLE,CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,FRONT LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INVERTER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING GENERAL PRECAUTIONARY STATIC&WIRE . . . . . . . .
DOOR,ACCESS TOOL COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LATCH,DOOR STRAIGHT LOOP CATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GUN/CABLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING ELECTRIC SHOCK CAN KILL SIGNIFICANT . . . . . . . . .
WHEEL,POLYPROPYLENE 10 IN X 2.25 WIDE . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,FLAT .812IDX1.469ODX.134T STL PLD ANSI.750 . . . . . . . . . . . . .
RING,RTNG EXT .750 SHAFT X .085 THK E STYLE PLD . . . . . . . . . . . . . . .
RACK,CYLINDER SINGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CASTER,SWVL 4.00 IN X 1.250 IN POLY−OLEFIN . . . . . . . . . . . . . . . . . . . . .
FAN,MUFFIN 24VDC 3000 RPM W/20.500 IN LEADS . . . . . . . . . . . . . . . . . . .
BEZEL,LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,SIDE LH LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LATCH,SLIDE FLUSH MTG HOLE 1.000 WIDEX 1.500 LG . . . . . . . . . . . . . .
ROUGHNECK C−4012 GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REGULATOR/FLOWMETER,10−50 CFH ARGON/MIX (350 MODEL) . . . . .
REGULATOR/FLOWMETER,0−50 CFH AR/CO2
W/FLOWTUBE(350P MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE,GAS 5FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE,WORK 10 FT NO1 W/CLAMP & BOOT
(350 MODEL) (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP,WORK 300 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COVER,CABLE BTRY POST BLK .75 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE,WORK 10 FT 1/O W/CLAMP & BOOT
(350P MODEL) (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP,WORK 300 AMP STL CHROME PLD W/COP CONTACTS . . . . . .
. . . . COVER,CABLE BTRY POST BLK .75 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TIP,FASTIP .312 OD .035 AND .030AL WIRES . . . . . . . . . . . . . . . . . . . . . . . . .
. . TIP,FASTIP .312 OD .045 AND .040AL WIRES . . . . . . . . . . . . . . . . . . . . . . . . .
. . MODULE, TACH (350 MODEL ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REGULATOR/FLOWMETER, 0−50 CFH CO2 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
5
5
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 39
1
. Hardware is common and
2
3
4
not available unless listed.
5
6
9
10
7
11
8
12
13
17
15
13
16
14
803 546-A
Figure 8-2. Baffle, Center w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7)
.. 1............
.. 2............
.. 3............
.. 4............
.. 5............
.. 6............
.. 7............
.. 8............
.. 9............
. 10 . . . . . . . . . . .
. 11 . . . . . . . . . . .
. 12 . . . . . . . . . . .
. 13 . . . . . . . . . . .
OM-1327 Page 40
058427
085980
605941
186437
057971
057745
186435
186436
198425
198426
212824
177307
134201
..
..
..
..
..
..
..
..
..
..
..
..
..
RING,RETAINING SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT,STL HEX FULL .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,FLAT STL .640 ID X 1.000 OD X 14GA THK . . . . . . . . . . . . . . . . . .
SPRING,CPRSN .845 OD X .110 WIRE X 1.500 . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,FLAT STL KEYED 1.500DIA X .125THK . . . . . . . . . . . . . . . . . . . . . .
SPRING,CPRSN 2.305 OD X .090 WIRE X 2.500 PLD . . . . . . . . . . . . . . . . . .
HUB,SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,BRAKE PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAP,FINISHING 1.19 X .37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAFFLE,CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REEL SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND−OFF SUPPORT,PC CARD .312/.375W/POST&LOCK .43 . . . . . . . .
1
1
1
1
1
1
1
1
2
2
1
1
10
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7) (Continued)
. 14 . . . . PC1 . . 220522
. 14 . . . . PC1 . . 222676
. . . . . . . . PLG7 . . 115092
. . . . . . . . PLG8 . 131056
. . . . . . PLG10,14 115091
. . . . . . PLG11,17 131054
. . . . . . PLG12,13,
27 . . 131204
. . . . . . . PLG16,
PLG27 131204
. . . . . . . . . . . . . . . . 213404
. . . . . . . . . . . . . . . . 213405
. . . . . . . . . . . . . . . . 168674
. 15 . . . . PC6 . . 216342
..
..
..
..
..
..
..
..
..
..
..
. . . . . . . . PLG29 131204
. . . . . . . . PLG30 . 115091
. 16 . . . . . . . . . . . 212843
. 17 . . . . . . . . . . . . Fig 8-6
..
..
..
..
CIRCUIT CARD ASSY,CONTROL W/PROGRAM (200/230V model) . . . . . . .
CIRCUIT CARD ASSY,CONTROL W/PROGRAM (460/575V model) . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE,INTERCONNECTING RS 485 INTERFACE TO CONTROL . . . . . . .
CABLE,INTERCONNECTING RS 485 INTERFACE TO PULSE OP . . . . . . .
CABLE,RIBBON 24 POSN 14.000 IN SKTS BE INVERTED . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,GMAW PULSE W/PROGRAM
(PULSE MODEL ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING,ADAPTER DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE ASSY,WIRE 4 ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 41
1
. Hardware is common and
2
not available unless listed.
32
3
31
30
7
29
28
4
27
5
8
6
26
25
9
24
10
23
22
11
12
13 14
16
21
20
19
18
17
15
803 552-A
Figure 8-3. Inverter Assy
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Inverter Assy (Fig 8-1 Item 9)
. . . 1 . . . . W . . . 188634
. . . . . . . C11,12,
13 . . 148240
. . . 2 . . . . . . . . . +212750
. . . . . . . . . . . . . . . . 185835
. . . 3 . . . . T1 . . 180952
. . . 4 . . . . L1 . . 216006
. . . 5 . . . . Z1 . . 212756
. . . 6 . . . SR1 . . 212937
. . . 7 . . . . T2 . . 213022
. . . 7 . . . . T2 . . 213024
. . . . . . . . PLG26 168071
. . . 8 . . . . . . . . . +212752
. . . 9 . . . CR1 . . 106462
. . . 10 . . . . . . . . . . 177547
. . . 11 . . . CT1 . . 213032
. . . 12 . . . . . . . . . . 025248
. . . 13 . . . . C1 . . 186015
. . . 13 . . . . C1 . . 193858
. . . 14 . . . C3,4 . 192935
. . CONTACTOR,DEF PRP 60A 3P 24VAC COIL W/COVER . . . . . . . . . . . . . . . . 1
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
. . . 14 . . . C3,4 . 217941 . .
. . . . . . . . . . . . . . . . 217942
. . . . . . . . . . . . . . . . 217040
. . . 15 . . . PC2 . . . 211125
. . . 15 . . . PC2 . . 219900
. . . . . . . . PLG2 . 168071
OM-1327 Page 42
..
..
..
..
..
CAPACITOR,CER DISC .003 UF 2000 VAC W/TERMS . . . . . . . . . . . . . . . . . .
WINDTUNNEL,LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . . .
XFMR,HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDUCTOR,INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STABILIZER,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT,DIODE POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR,CONTROL 200/230 PRI 48CT/36CT/16.7/20.0 SEC . . . . . . . . . . . . . . .
XFMR,CONTROL 460/575 PRI 48CT/36CT/16.7/20.0 SEC . . . . . . . . . . . . . . .
HOUSING PLUG PINS+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNEL,RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY,ENCL 24VDC DPDT 20A/120VAC 8PIN FLANGE MTG . . . . . . . . . . .
BUSHING,SNAP−IN NYL CT−MOUNT 1.125 MTG HOLE . . . . . . . . . . . . . . . .
XFMR,CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND−OFF,INSUL .250−20 X 1.250 LG X .437 THD . . . . . . . . . . . . . . . . . . .
CAPACITOR,POLYP FILM .34 UF 1000 VAC +8% −0% (200/230V model) .
CAPACITOR,POLYP FILM .27 UF 1000 VAC +8% −0% (460/575V model) .
CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA
(200/230 MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR,ELCTLT 1800 UF 500 VDC CAN 2.52 DIA
(460/575 MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER,NYLON CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT,NYLON M12 THREAD CAPACITOR MOUNTING . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,INTERCONNECT (200/230) . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,INTERCONNECT (460/575) . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG PINS+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . .
3
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Inverter Assy (Fig 8-1 Item 9) (Continued)
. . . 16 . . . . . . . . . . 185835
. . . 17 . . . . . . . . . . 175140
. . . . . . . . . . . . . . . . 178591
. . . 18 . . . . . . . . . . . 181197
. . . 19 . . . L3,4 . . 175482
. . . 20 . . . . . . . . . . 109056
. . . 21 . . PM1,2 . 212936
. . . 22 . . . RT2 . . 213029
. . . 23 . . . . . . . . . . 212776
. . . 24 . . . . . . . . . . 212753
. . . 25 . . . . . . . . . . 175255
. . . 26 . . . . . . . . . . 214537
. . . 27 . . . . . . . . . . 181853
. . . 28 . C2,R1,C5 175194
. . . 29 . . . RT1 . . 213028
. . . 30 . . . D1,2 . 201531
. . . 31 . . . . . . . . . . 199840
. . . 32 . . . . . . . . . . 179276
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LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . . .
BRACKET,DI−DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,CONNECTION DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET,DI−DT RUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL,DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORE,FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE . . . . . . . . . . . . . . . .
KIT,TRANSISTOR IGBT MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR,NTC 30K OHM @ 25 DEG C 26IN LEAD 3P . . . . . . . . . . . . . .
HEAT SINK,POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK,RECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR,RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER,ACCESS FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR,SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR/CAPACITOR, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR,NTC 30K OHM @ 25 DEG C 26IN LEAD 2P . . . . . . . . . . . . . .
KIT,DIODE POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR,DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE CENT . . . . . . . . . . .
1
1
1
1
2
2
2
1
1
1
1
1
4
1
1
2
2
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 43
. Hardware is common and
3
not available unless listed.
4
2
1
5
6
13
12
14
11
Dia.
Mkgs.
8
9
10
Item
No.
7
803 547-A
Figure 8-4. Panel, Front w/Components
Part
No.
Description
Quantity
Figure 8-4. Panel, Front w/Components (Fig 8-1 Item 23)
. . . 1 . . . . . . . . . . 212837
. . . 2 . . . . . . . . . . 212845
. . . 3 . . . . . . . . . . 212819
. . . 4 . . . . . . . . . . 212825
. . . 5 . . . . C8 . . 200953
. . . 6 . . . . . . . . . . 048282
. . . . . . . . C9,10 . 080894
. . . 7 . . . . . . . . . . 190363
. . . 8 . . . . S1 . . 128756
. . . 9 . . . PC3 . . 212979
. . . . . . . . PLG18 . 115094
. . . . . . . . PLG19 135560
. . . . . . . . PLG28 131055
. . . 10 . . . . . . . . . . 213936
. . . 11 . . . . . . . . . . 212847
. . . . . . . . . . . . . . . . 218551
. . . . . . . . . . . . . . . . 215232
. . . . . . . . . . . . . . . . 213934
. . . . . . . . . . . . . . . . 213935
. . . 12 . . . . . . . . . . 212955
. . . 13 . . . . . . . . . . 213134
. . . 14 . . . . . . . . . . 210398
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HANDLE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEZEL,UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENCLOSURE,CIRCUIT CARD ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODULE,FILTER .1MF 500VDC 10 CKT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RCPT W/SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR,CER DISC .01 UF 1000 VDC 20% NYLEZ . . . . . . . . . . . . . . . . .
RCPT W/SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH,TGL 3PST 40A 600VAC SCR TERM WIDE TGL . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,USER INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,POWER/MIG GUN/SPOOLGUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEZEL,DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTION,FLIPCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP,COMPONENT .580H X .715W ADH BACK . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,NAMEPLATE MM350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,NAMEPLATE MM350P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,CONTROLS USER INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB,ENCODER 1.670 DIA X .250 ID PUSH ON W/SPRING . . . . . . . . . . . .
BUSHING,SNAP−IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 44
. Hardware is common and
1
not available unless listed.
2
3
4
9
8
7
5
6
803 549-A
Item
No.
Dia.
Mkgs.
Figure 8-5. Panel, Rear w/Components
Part
No.
Description
Quantity
Figure 8-5. Panel, Rear w/Components (Fig 8-1 Item 10)
. . . 1 . . . . . . . . . . 212820
. . . 2 . . . . . . . . . . 169654
. . . 3 . . . . . . . . . . 200285
. . . 4 . . . . . . . . . . 188441
. . . 5 . . . . . . . . . . 137761
. . . 6 . . . GS1 . . 216395
. . . 7 . . . . . . . . . . 010467
. . . 8 . . . . . . . . . . 212772
. . . . . . . . . . . . . . ♦213 380
. . . 8 . . . . . . . . . . 213018
. . . . . . . . . . . . . . . . 213908
. . . 9 . . . . . . . . . . 214654
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PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,SUPPORT TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING CYLINDER MAY EXPLODE IF DAMAGED . . . . . . . . . . . .
CHAIN,WELDLESS 2/0 X 31. BRIGHT ZINC PLD . . . . . . . . . . . . . . . . . . . . . . .
NUT, 750NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, 34VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT . . . . . . . . . . . . . . .
CONN,CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE,POWER 10 FT 6IN 6GA 4C (200/230V) . . . . . . . . . . . . . . . . . . . . . . . .
PLUG,STR GRD 2P3W 50A 250VAC *6−50P . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE,POWER 10 FT 6 IN 10GA 4C (460/575V) . . . . . . . . . . . . . . . . . . . . . . .
PLATE,ADAPTER POWER CORD (575 MODEL ONLY) . . . . . . . . . . . . . . . . .
LABEL,WARNING ELECTRIC SHOCK/INPUT POWER . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 45
. Hardware is common and
See Table 8-1
Drive Roll & Wire Guide Kits.
not available unless listed.
13
12
18
11
10
20
19
9
35
36
26
27
1
8
6
7
24
37
28
39
38
14
26
27
25
20
19
21
32
30
31
23
22
26
3
9
20
28
5
10
26
27
27
33
17
2
15
29
28
19
16
4
11
12
13
34
Ref. 803 548-A
Figure 8-6. Wire Drive Assembly
Item
No.
Dia.
Mkgs.
Part
No.
213137
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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OM-1327 Page 46
216409
212844
166337
194521
166071
166338
079634
151828
085242
085244
196896
196897
196895
010224
079633
195640
079240
601966
602213
602242
601872
108943
221 654
Description
Quantity
Figure 8-6. Wire Drive Assembly
. . . . MOTOR,GEAR 24VDC 150RPM 24:1 RATIO W/TACH . . . . . . . . . . . . . . . . .
. . . . INSULATOR,DRIVE HOUSING 4 ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING,ADAPTER GUN/FEEDER (SALABLE AS 046621) . . . . . . . . . . .
. . . . INSULATOR,DRIVE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LEVER,MTG PRESSURE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LEVER,MTG PRESSURE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PIN,HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PIN,COTTER HAIR .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FASTENER,PINNED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER,CUPPED .328IDX .812ODX16GAX.125 LIP . . . . . . . . . . . . . . . . .
. . . . CUP,SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SPRING,CPRSN .695 OD X .095 WIRE X 1.500 . . . . . . . . . . . . . . . . . . . . . .
. . . . KNOB,TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PIN,SPRING CS .187 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FTG,HOSE BRS BARBED NIPPLE 3/16 TBG . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW,M 6−1.0X 16 FLATHD−PHL STL PLD . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW,375−16X1.75 HEX HD−PLN STL PLD FULL THRD . . . . . . . . . . . .
. . . . SCREW,375−16X1.25 HEX HD−PLN GR5 PLD . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER,LOCK .380IDX0.691ODX.115T STL PLD SPLIT.375 . . . . . . . . . .
. . . . WASHER,FLAT .375IDX0.875ODX.083T STL PLD . . . . . . . . . . . . . . . . . . . .
. . . . NUT, 375−16 .56HEX .34H STL PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW,250−20X1.50 HEXWHD.61D GR5 PLD . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER,SHLDR INSULATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
2
2
2
2
2
2
1
3
1
1
3
1
1
2
2
Item
No.
Dia.
Mkgs.
Part
No.
Description
213137
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24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
089800
602154
166072
172075
602009
173618
195802
602241
174609
604538
204585
045127
602169
056193
056207
189285
Quantity
Figure 8-6. Wire Drive Assembly (Continued)
. . . . NUT, 250−20 .44HEX .22H STL PLD .58D FLANGE DEFOR . . . . . . . . . . . .
. . . . SCREW,250−20X .50 HEXWHD.50D STL PLD SLFFMG TAP−RW . . . . . .
. . . . SPACER,GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CARRIER,DRIVE ROLL W/COMPONENTS 24 PITCH . . . . . . . . . . . . . . . . .
. . . . SCREW,250−20X1.25 SOC HD−HEX GR8 PLN . . . . . . . . . . . . . . . . . . . . . . .
. . . . CARRIER,DRIVE ROLL 10MM SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER,FLAT .175IDX0.590ODX.040T STL PLD . . . . . . . . . . . . . . . . . . . .
. . . . WASHER,FLAT .281IDX0.625ODX.065T STL PLD ANSI.250 . . . . . . . . . . .
. . . . SCREW,M 4− .7X 12 CHEESE HD BLK DIN 84 . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER,FLAT .344IDX0.688ODX.065T STL PLD ANSI.312 . . . . . . . . . . .
. . . . KNOB,FLUTED 1.75 IN W/ .312−18 STUD 1.00 LG . . . . . . . . . . . . . . . . . . .
. . . . GUIDE,WIRE INLET ANTI−WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW,SET # 8−32X .18 CUP PT SCH STL PLN . . . . . . . . . . . . . . . . . . . .
. . . . GUIDE,WIRE INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . GUIDE,WIRE INTERMEDIATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ROLL,DRIVE V GROOVE .035−.045 WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
4
4
1
1
2
1
1
1
1
1
1
1
4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Table 8-1. Drive Roll And Wire Guide Kits
Note
Base selection of drive rolls upon the following recommended usages:
1
2
3
4
V-Grooved rolls for hard wire.
U-Grooved rolls for soft and soft shelled cored wires.
V-Knurled rolls for hard shelled cored wires.
Drive roll types may be mixed to suit particular requirements (example: 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
OM-1327 Page 47
Item
Number
1
2
3
Figure 8-7. Consumables Flowchart
OM-1327 Page 48
4
5,7
Item
No.
Part
No.
Description
Quantity
Figure 8-7. Consumables Flowchart
Table 8-2. Nozzles
. . . 1 . . . . . . . . . ♦176238 . . NOZZLE, spot flat (requires diffuser 209099, used with any
heavy duty FasTipt contact tip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . ♦176240 . . NOZZLE, spot inside corner (requires diffuser 209099, used with any
heavy duty FasTipt contact tip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . ♦176242 . . NOZZLE, spot outside corner (requires diffuser 209099, used with any
heavy duty FasTipt contact tip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 610 . . NOZZLE, screw on brass 1/2 in orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 611 . . NOZZLE, screw on brass 3/4 in orifice straight . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 612 . . NOZZLE, screw on brass 3/4 in orifice straight heavy duty . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 613 . . NOZZLE, screw on brass 5/8 in orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 614 . . NOZZLE, screw on brass 5/8 in orifice heavy duty . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 615 . . NOZZLE, screw on copper 1/2 in orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 616 . . NOZZLE, screw on copper 3/4 in orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦199 617 . . NOZZLE, screw on copper 3/4 in orifice heavy duty . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . 198 855 . . NOZZLE, screw on copper 5/8 in orifice (standard on 300 & 400
amp models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . 199 618 . . NOZZLE, screw on copper 5/8 in orifice heavy duty
(standard on 500 & 600 amp models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦207 313 . . NOZZLE, screw on copper 5/8 in orifice 15/16 OD . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . ♦209 033 . . NOZZLE, slip on copper 1/2 in orifice tapered (requires diffuser 209031 or
209032 and insulator 209047, used with any tapered FasTipt contact tip) . .
. . . 1 . . . . . . . . ♦209 034 . . NOZZLE, slip on copper 3/8 in orifice tapered (requires diffuser 209031 or
209032 and insulator 209047, used with any tapered FasTipt contact tip) . .
. . . 1 . . . . . . . . ♦209 035 . . NOZZLE, screw on copper 3/8 in orifice tapered (requires diffuser 206195,
206196 or 210664, used with any tapered FasTipt contact tip) . . . . . . . . . . .
. . . 1 . . . . . . . . ♦209 036 . . NOZZLE, screw on copper 1/2 in orifice tapered (requires diffuser 206195,
206196 or 210664, used with any tapered FasTipt contact tip) . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Table 8-3. Heavy Duty FasTiptContact Tips*
...
...
...
...
...
...
...
...
...
...
2
2
2
2
2
2
2
2
2
2
. . . . . . . . ♦206 184
. . . . . . . . ♦206 185
. . . . . . . . ♦206 186
. . . . . . . . ♦206 187
. . . . . . . . . . 206 188
. . . . . . . . ♦206 189
. . . . . . . . . . 206 190
. . . . . . . . ♦206 191
. . . . . . . . ♦206 192
. . . . . . . . ♦206 193
..
..
..
..
..
..
..
..
..
..
.023 in (0.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.030 in (0.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.035 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.040 in (1.0 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.045 in (1.2 mm) (standard on 300 & 400 amp models) . . . . . . . . . . . . . . . . . . .
.052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire . . . . . . . . . . . . . . . . . . . . .
1/16 in (1.6 mm) (standard on 500 & 600 amp models) . . . . . . . . . . . . . . . . . . .
.068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire . . . . . . . . . . . . . . . . . . . . .
5/64 in (2.0 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/32 in (2.4 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
Table 8-4. Extra Heavy Duty FasTiptContact Tips*
...
...
...
...
...
...
...
...
...
2
2
2
2
2
2
2
2
2
........
........
........
........
........
........
........
........
........
♦199 605
♦199 606
♦198 851
♦198 852
♦198 853
♦198 854
♦199 607
♦199 608
♦199 609
..
..
..
..
..
..
..
..
..
.035 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.040 in (1.0 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.045 in (1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire . . . . . . . . . . . . . . . . . . . . .
1/16 in (1.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire . . . . . . . . . . . . . . . . . . . . .
5/64 in (2.0 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/32 in (2.4 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7/64−1/8 in (2.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
OM-1327 Page 49
Item
No.
Part
No.
Description
Quantity
Figure 8-7. Consumables Flowchart (Continued)
Table 8-5. Tapered FasTipt Contact Tips*
...
...
...
...
...
...
...
2
2
2
2
2
2
2
.........
.........
.........
.........
.........
.........
.........
♦209024
♦209025
♦209026
♦209027
♦209028
♦209029
♦209030
..
..
..
..
..
..
..
.023 in (0.6 mm)
.030 in (0.8 mm)
.035 in (0.9 mm)
.045 in (1.2 mm)
3/64 in (1.2 mm)
.052 in (1.3 mm)
1/16 in (1.6 mm)
....................................................
....................................................
....................................................
....................................................
....................................................
....................................................
....................................................
1
1
1
1
1
1
1
Table 8-6. Value Multi−Turn Contact Tips*
...
...
...
...
...
...
...
...
...
...
2
2
2
2
2
2
2
2
2
2
........
........
........
........
........
........
........
........
........
........
♦087 300
♦071 825
♦054 202
♦054 201
♦199 593
♦044 006
♦047 566
♦202 933
♦199 594
♦047 565
..
..
..
..
..
..
..
..
..
..
.023 in (0.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.030 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.035 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.045 in (1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.3/64 in (1.2 mm) aluminum wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.052 in (1.3 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/16 in (1.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/16 in (1.6 mm) aluminum wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.068 in (1.7 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5/64 in (2.0 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
Table 8-7. Gas Diffusers
...
...
...
...
...
3
3
3
3
3
. . . . . . . . ♦198 857
. . . . . . . . ♦199 623
. . . . . . . . ♦199 621
. . . . . . . . ♦199 622
. . . . . . . . . . 206 195
..
..
..
..
..
. . . 3 . . . . . . . . ♦210 664 . .
. . . 3 . . . . . . . . ♦206 196 . .
. . . 3 . . . . . . . . ♦209 031 . .
. . . 3 . . . . . . . . ♦209 032 . .
. . . 3 . . . . . . . . ♦209 099 . .
1/8 in tip recess − for extra heavy duty FasTip contact tips . . . . . . . . . . . . . . . .
Flush tip − for extra heavy duty FasTip contact tips . . . . . . . . . . . . . . . . . . . . . .
1/8 in tip recess − for value multi−turn contact tips . . . . . . . . . . . . . . . . . . . . . . .
Flush tip − for value multi−turn contact tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/8 in tip recess − for heavy duty FasTip contact tips
(standard on all guns) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/4 in tip recess − for heavy duty FasTip contact tips . . . . . . . . . . . . . . . . . . . . .
Flush tip − for heavy duty FasTip contact tips . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slip on recessed diffuser (requires nozzle 209033 or 209034
and insulator 209047, used with any tapered FasTip contact tip) . . . . . . . . . .
Slip on flush diffuser (requires nozzle 209033 or 209034
and insulator 209047, used with any tapered FasTip contact tip) . . . . . . . . . .
Spot diffuser (requires spot nozzle 176238 or176240 or 176242) . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
Table 8-8. Insulators
. . . 4 . . . . . . . . . . 198 856 . . INSULATOR, Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 209 047 . . INSULATOR, Teflon (required when using diffuser 209031 or 209032
with nozzle 209033 or 209034) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 202 292 . . COVER, nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 8-9. Liners
. . . 6 . . . . . . . . ♦202 889 . . LINER, monocoil .023−.030 wire x 16.5 ft round wound . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . 202 890 . . LINER, monocoil .035−.045 wire x 16.5 ft round wound
(standard on 300 & 400 amp models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . 202 891 . . LINER, monocoil .052−1/16 wire x 16.5 ft round wound
(standard on 500 & 600 amp models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . ♦202 892 . . LINER, monocoil 1/16−.078 wire x 16.5 ft flat wound . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . ♦202 893 . . LINER, monocoil 5/64−3/32 wire x 16.5 ft flat wound . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . ♦202 894 . . LINER, monocoil 7/64−1/8 wire x 16.5 ft flat wound . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . ♦202 895 . . LINER, monocoil 3/64−1/16 AL wire x 16.5 ft . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 50
1
1
1
1
1
1
1
Item
No.
Part
No.
Description
Quantity
Figure 8-7. Consumables Flowchart (Continued)
Table 8-10. Goosenecks
. . . 7 . . . . . . . . +199 625 . . GOOSENECK, jacketed 4.5 in/50deg wrench swivel
(standard on 300 & 400 amp models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . +199 626 . . GOOSENECK, jacketed 6 in/50deg wrench swivel
(standard on 500 amp models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . +199 627 . . GOOSENECK, jacketed 8 in/50deg wrench swivel
(standard on 600 amp models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . +♦213 450 . . GOOSENECK, jacketed 6.0” straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
♦OPTIONAL
+Includes nozzle insulator 198 856 and threaded nut cover 202 292.
*All contact tips are packaged in bags of 25.
BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model is required when ordering parts from your local distributor.
Standard Consumables Chart
Contact Tip
206 188
Nozzle
198 855
Diffuser
206 195
Liner
202 890
Gooseneck
199 625
OM-1327 Page 51
12
13
11
10
14
16
15
8
9
7
5
8
1
2
3
4
6
For consumable items 1 thru 7
see Figure 8-7.
802 630-C
Figure 8-8. 4012 Gun
OM-1327 Page 52
Item
No.
Part
No.
Description
Quantity
Figure 8-8. 4012 Gun
. . . 8 . . . . . . . . . . 199 630
. . . . . . . . . . . . . . . . 199 632
. . . . . . . . . . . . . . . . 199 633
. . . . . . . . . . . . . . . . 199 634
. . . . . . . . . . . . . . . . 199 635
. . . . . . . . . . . . . . . . 199 647
. . . 8 . . . . . . . . . . 199 631
. . . . . . . . . . . . . . . . 199 632
. . . . . . . . . . . . . . . . 199 633
. . . . . . . . . . . . . . . . 199 647
. . . 9 . . . . . . . . . . 199 652
. . . 10 . . . . . . . . . . 199 637
. . . 11 . . . . . . . . . . 199 640
. . . 12 . . . . . . . . . . 079 974
. . . 13 . . . . . . . . . . 079 878
. . . . . . . . . . . . . . . . 079 531
. . . 14 . . . . . . . . ♦199 661
. . . 15 . . . . . . . . . . 199 628
. . . 16 . . . . . . . . . . 199 629
. . . . . . . . . . . . . . ♦199 662
. . . . . . . . . . . . . . ♦199 663
. . . . . . . . . . . . . . . . 202 916
. . . . . . . . . . . . . . . . 201 727
. . . . . . . . . . . . . . ♦199 664
. . . . . . . . . . . . . . . . 202 918
. . . . . . . . . . . . . . . . 201 728
. . HANDLE KIT, 300 & 400 amp models (includes) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, M4 x 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, M3 x 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL, gun handle Miller Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE KIT, 500 & 600 amp models (includes) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, M4 x 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL, gun handle Miller Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, back-end C-4012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, machine binding head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, Miller power pin (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, Miller power pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING, plug and pins (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONN, circ cpc clamp str rlf size 11 .453 OD . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, locking trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, trigger (standard on all guns) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, contact pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOOK, gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, adapter Miller to old Hobart/Thermal/Tweco (includes) . . . . . . . . . . . . . . .
. . . . ADAPTER, Roughneck to old Hobart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTROL LEADS, Hobart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, adapter Miller to Lincoln (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ADAPTER, Roughneck to Lincoln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTROL LEADS, Lincoln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
4
1
1
2
1
4
4
2
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
♦OPTIONAL
BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model is required when ordering parts from your local distributor.
OM-1327 Page 53
Notes
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 6/04
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2004 Miller Electric Mfg. Co. 10/04
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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