Miller | KJ159518 | Owner Manual | Miller MILLERMATIC 400 User manual

Miller MILLERMATIC 400 User manual
OM-189 424C
July
Miller
1998
Processes
MIG
(GMAW) Welding
Flux Cored
The Power ofBlue.
(FCAW) Welding
Description
Arc
Welding
Power Source
and Wire Feeder
Millermatic 400
p
Visit
our
website at
www.MitlerWelds.com
OWNERS
MANUAL
From Miller to You
Thank you and
you
can
get the
you dont
Thats
congratulations on choosing Miller. Now~
job done and get it done right. We know
have time to do it any other way.
why
when Niels Miller first started
building arc
sure his products offered
value
and
long-lasting
superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
welders in 1929, he made
Today,
the
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
~I~1ftflflR~
L~
Weridug aebard as you do~ every
This Owners
Miller
help
Manual is
products.
you protect
designed
help you get the most out of your
Please take time to read the Safety precautions. They will
to
yourself against potential
hazards
on
vower source frow Mliter Is
hacked by the must hassle-tree
warranty In the kusluess.
the worksite. Weve
made installation and
operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
iI~1iIlluIiW
REGISTERED
QUALITY SYSTEM
some reason
Miller is the first welding equipment
manufacturer in the U.S.A. to he
registered to the ISO 9001 Uuality
System Standard.
the unit needs
repair,
theres
.
a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller offers a Technical
Manual which provides
more
detailed service and
parts information for your:
unit To obtain a Technical
centact yÆur local
thstributor YOur distributor
can also supply you with.
Manual~
Welding Process Manuals
as SMAW:GTAW,
GM4~andGMAWP.
such
Miller Electric manufactures
of welders and
welding
For information
products,
on
a
full line
related
other
equipment.
quality Miller
contact your local Miller
to receive the
latest full line
distributor
catalog
or
.
individual
catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
_
f//A Miller
The Power QfBhse
TABLE OF CONTENTS
following term is
interchangeably
throughout this manual:
The
SECTION 1
-
SAFETY PRECAUTIONS
-
READ BEFORE USING
used
MIG=GMAW
1-4.
Symbol Usage
Arc Welding Hazards
Additional Symbols For Installation, Operation,
Principal Safety Standards
1-5.
EMF Information
1-1.
1-2.
1-3.
SECTION 1
1-1.
1-2.
1-3.
-
1
1
And Maintenance
-
Principales
normes
1-5.
Information
sur
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
es
5
avec
Iinstallation,
8
champs electromagnetiques
SECTION 3
3-1.
-
-
10
11
11
12
12
13
Connecting Input
Wire
15
16
1.7
OPERATION
17
MAINTENANCE &TROUBLESHOOTING
18
4-1.
Routine Maintenance
18
4-2.
Circuit Breaker CB1
18
4-3.
Unit Overload
4-4.
Changing Drive Roll
Aligning Drive Rolls
Troubleshooting
4-5.
4-6.
SECTION 5
SECTION 6
-
-
WARRANTY
OM-1 89424C
9
10
14
Power
Controls
SECTION 4
9
14
Location and
Selecting
Threading Welding
8
9
Specifications
Duty Cycle And Overheating
Volt-Ampere Curve
Installing Work Clamp
Installing Welding Gun (Gun Not Included)
Setting Gun Polarity For Wire Type
Remote 14 Receptacle
Installing Gas Supply
Installing Wire Spool and Adjusting Hub Tension
2-11. Electrical Service Guide
2-13.
le fonctionnement
7
de sØcuritØ
INSTALLATION
a
5
5
2-10. Inductance Selection
2-12.
3
LIRE AVANT UTILISATION
et Ia maintenance
1-4.
-
3
4
CONSIGNES DE SECURITE
Signification des symboles
Dangers relatifs au soudage a arc
Dangers supplØmentaires en relation
SECTION 2
1
18
and Wire Inlet Guide
and Wire Guide
19
19
20
ELECTRICAL DIAGRAIvt
21
PARTS LIST
22
.
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
nd5/97
som
Symbol Usage
Si -1.
A
Out!
There
shown in the
Marks
special safety
a
The
hazards
are
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
message.
safety
actions to avoid the hazards.
related.
Welding Hazards
Arc
1-2.
not
possible
are
procedure! The possible
adjoining symbols.
hazards with this
flT Means Note~
A
Watch
Warning!
Means
41
are used throughout this manual
identity possible hazards. When you
shown below
symbols
to call attention to and
symbol, watch out, and followthe related instructions
safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1 -4. Read and
follow all Safety Standards.
see
the
to avoid the hazard. The
A Only qualified persons should install, operate, maintain,
repair this unit.
A
and
During operation, keep everybody, especially children, away.
grounding
If earth
with
kill.
work
Use
Wear
hole-free
dry,
and
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
a
Keep
all
Clamp
harness if
safety
Wear
panels
and
worktable
as near
working
single
a
to
the weld
is
required,
use
for the
remote
welding
output
or
if
input power
before
clamp when not connected
object.
workpiece to prevent
to
one
electrode
or
work cable to any
inverters.
on
touching any parts.
process.
control if
Properly
present
on
this
install and
ground
this
equipment according
I
can
be hazardous.
to its
J
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
remove welding fumes and gases.
If ventilation is poor,
Read
Material
the
manufacturers
Work in
a
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.
wearing
an
making input connections,
conductor first
-
attach
proper
grounding
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
use
equipment
worn,
drape
when not in
cables
over
your
or
poorly spliced
approved air-supplied respirator.
Safety
Data
Sheets
(MSDS5)
instructions for metals, consumables,
Do not weld in locations
form
use.
body.
to
and
the
coatings,
only if it is well ventilated, or while
air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
highly
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
Do not weld
can
or
spraying
react with vapors to
cables.
on
coated metals, such
as
galvanized, lead,
or
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.
cadmium
damaged, undersized,
arc
-
-
Turn off all
exhaust at the
confined space
operations.
double-check connections.
use an
use
cleaners, and degreasers.
Manual and national, state, and local codes.
-
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Welding produces
~
Keep your
input power or stop engine before installing or
equipment. Lockout/tagout input power according
OSHA 29 CFR 191 0.147 (see Safety Standards).
Do not
workpiece
practical.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
~
Disconnect
Do not
as
SIGNIFICANT DC VOLTAGE exists after removal of
-
output ONLY if required
servicing
When
place.
metal-to-metal contact to
good
FUMES AND GASES
AC output in damp areas, if movement is confined,
danger of falling.
output
Owners
in
output terminal.
weld
body protection.
unit.
to
above floor level.
securely
covers
work cable with
ground using dry insulating mats
prevent any physical contact with the
use
Use AC
If AC
ground,
parts.
insulating gloves
yourself
or covers big enough
work or ground.
there is
directly
from work and
Insulate
Do not
it
work cable.
parts
Do not connect more than
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.
Do not touch live electrical
or
contact with any metal
live
Touching
clamp
Do not touch electrode if you are in contact with the work,
another electrode from a different machine.
Insulate work
can
is
use
or
or
ELECTRIC SHOCK
-
required, ground
workpiece
do not
of the
separate cable
a
plated steel,
unless the
OM-189 424
Page
1
ARC RAYS
I:BUILDUpOFGAS
burn eyes and skin
can
Shut off
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Always
can
injurerk1IL
shielding gas supply when
confined
ventilate
not in use.
spaces
use
or
approved air-supplied respirator.
Wear
awelding helmetfitted with a proper shade offilterto protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
Wear
approved safety glasses
I
HOT PARTS
can cause severe
burns
with side shields under your
helmet.
Do not touch hot parts bare handed.
Use protective screens
or
barriers to
protect others from flash and
Allow
arc.
torch.
glare;
warn
Wear
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
others not to watch the
cooling period
before
working
on
gun
or
material
MAGNETIC FIELDS
WELDING
cause fire
can
Welding
on
drums,
pipes,
or
explosion.
Pacemaker
Protect
yourself
and others from
Do not weld where
flying sparks
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
cover
(10.7 m)
NOISE
fire,
and
that
welding
aware
can cause
fire
Do not weld
on
on
keep
a
fire
on a
of the
welding
approved
closed containers such
Connect work cable to the work
Noise from
arc.
Wear
as
tanks, drums,
as
approved
CYLINDERS
or
or
equipment
can
ear
protection
if noise level is
explode
can
if
damaged.
welder to thaw frozen
when not in
welding
Protect
cut off
welding
wire at
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Keep cylinders away from any welding
protective garments
shirt, cuffless trousers, high shoes, and
such
as
a
leather
gloves, heavy
cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
lighter or matches,
Never
drape
Never allow
Never weld
a
a
welding
welding
on a
torch
over a
or
gas
other electrical circuits.
cylinder.
electrode to touch any
pressurized cylinder
-
cylinder.
explosion
will result.
Use
FLYING METAL
can
.
mechanical shocks,
Install
use.
Wear oil-free
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.
area as
pipes.
or
Shielding
pipes,
(see
to AWS F4.1
close to the
Remove stick electrode from holder
tip
processes
high.
partition
or
prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
contact
some
If
covers.
to
use
damagehearing.
the hidden side.
they are properly prepared according
Safety Standards).
Do not
spot
extinguisher nearby.
ceiling, floor, bulkhead,
unless
practical
can
or
damage hearing.
welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Be
keep away.
and hot metal.
Be alert that
Watch for
pacemakers.
going near arc welding, gouging,
welding operations.
strike flammable material.
them with
wearers
affet
Wearers should consult their doctor before
closed containers, such as tanks,
can cause them to blowup. 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 surethe
area is safe before doing any welding.
or
can
injure eyes.
only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
Turn face away from valve outlet when
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
opening cylinder
and
and
valve.
Keep protective cap in place over valve except when cylinder is
use or
connected for
Read and follow instructions
associated
in
use.
equipment,
on
and CGA
compressed gas cylinders,
publication P-i listed in Safety
Standards.
.
OM-189 424
Page
2
1-3.
Additional
Symbols
For
Installation, Operation, And Maintenance
MOVING PARTS
FIRE OR EXPLOSION hazard;
Do not install
place
or
unit on, over,
flammables.
building wiring be sure power supply system
properly sized, rated, and protected to handle this unit.
Do not overload
is
near
Injury
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
or near
combustible surfaces.
Do not install unit
can cause
-
FALLING UNIT
can cause
injury.
HF. RADIATION
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
can cause
interference.
Use
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
support unit.
only qualified persons familiar with
equipment perform this installation.
Have
using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
If
electronic
The
unit.
is
user
responsible
having a qualified electrician
problem resulting from the
for
correct any interference
installation.
promptly
OVERUSE
Allow
cooling period;
Reduce current
starting
Put
or
to weld
Do not block
STATIC
or
(ESD)
on
handling
OVERHEATING
can cause
follow rated
reduce
duty cycle.
duty cycle
before
again.
grounded
boards
or
damage PC
wrist
strap
by
at once.
Have the installation
.
filter airflow to unit.
can
the FCC about interference, stop
If notified
equipment
regularly
using
the
checked and maintained.
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
boards.
BEFORE
parts.
ARC WELDING
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
can cause
interference.
Electromagnetic energy can interfere with
electronic equipment such as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury.
Keep
away from
Keep away
moving parts.
from
pinch points
robots.
as
all equipment in the welding
electromagnetically compatible.
Be
such
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE
can cause
injury;
Be
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
sure
according
Do not press gun
trigger
until instructed to do
is
close
Locate
tronic
area
this
welding
100 meters from any sensitive elec
machine is
installed
and
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
such
point gun toward any part of the body,
people, or any metal when threading
welding wire.
using
Do not
line
filters,
or
shielding
the work
area.
other
I -~
Prinr~in~I Sif~h, St~ndirrI~
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical
Code, NFPA Standard 70, from National Fire
Protection Association,
Batterymarch Park, Quincy,
MA 02269.
Safe
Handling
of
Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 RexdaJe
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Code for Safety in
Safe Practices For
Occupation
And Educational
Eye
And Face
Protection, ANSI Standard Z87. 1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-189 424
Page
3
EMF Information
1-5
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
1.
Keep
Welding current, as it flows through welding cables, will cause electro
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of reseajch, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees 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
2.
Arrange cables
3.
Do not coil
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding
To
or
reduce
cutting.
magnetic fields
procedures:
4.
or
together by twisting
or
taping
to one side and away from the
drape
Keep welding power
tor as
5.
cables close
cables around your
source
and cables
them.
operator.
body.
as
far away from opera
practical.
Connect work
clamp
to
workpiece
as
close to the weld
as
possible.
About Pacemakers:
in the
workplace,
use
the
following
Pacemaker wearers consult your doctor first. If cleared by your doctor,
following the above procedures is recommended.
then
.
.
OM-189 424 Page 4
SECTION 1
CONSIGNES DE SECURITE
UTI LISATION
-
LIRE AVANT
-
_nd_fre 5/97
sorn
1-1
Signification
.
symboles
Signifie Mise en garde! Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
a
A
des
Identitie
message de sØcuritØ
un
Ce groupe de symboles signifie Mise en garde! Soyez vigilant II y a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECES CHAUDES.
~
Signifie
A
NOTA ; nest pas relatif a Ia sØcuritØ.
Dangers relatifs
1-2.
Les
au
soudage a
Iarc
symboles presentes ci-aprŁs
present
risques
vigilant
danger.
sont utilisØs tout au long du
manuel pour attirer votre attention et identifier les
de danger. Lorsque vous voyez un symbole, soyez
et suivez les directives mentionnØes afin dØviter tout
Les consignes de sØcuritØ presentees ci-aprŁs ne font
que rØsumer linformation contenue dans les normes de sØcuritØ
ØnumØrØes a Ia section 1 -4. Veuillez lire et respecter toutes ces
normes de sØcuritØ.
A
Iutilisation, lentretien
Linstallation,
vent Œtre confiØs
A
Au
cours
de
qu
des personnes
et tes
reparations
qualifiees.
ne
doi
lutilisation, tenirtoute personne a lØcartet plus par
ticuliŁrement les enfants.
Ne pas toucher lŁlectrode
terre ou une
toucher
jamais
es
piŁces Łlectriques
Porter des gants et des vŒtements de
pas de trous.
sous
protection
Porter
un
harnais de sŁcuritŁ
Maintenir solidement
Ne pas
se
servir de
source
electrique
humides, dans les endroits confines
Se servir dune
procØdØ
de
source
soudage
Si lutilisation dune
saire,
se
ou
l oª
secs ne
risque
electrique courant Ølectrique
Ølectrique
courant
Ia
en
quand
place
on
travaille
en
hauteur.
tous lea panneaux et
capots.
pince de masse quand pas
objet metallique.
mis a Ia
piŁce
pour Øviter Ie contact
tout
fly a DU COURANT CONTINU IMPORTANT dans les
convertisseurs aprŁs Ia suppression de Ialimenta
tion Ølectrique.
ArrŁter lea convertisseurs, dŁbrancher le courant
charger lea condensateurs dalimentation
indiquŁes dans Ia partie entretien avant de
Łlectrique,
et dŁ
selon les instructions
toucher les
piŁces.
comportant
dans les
LES
Œtre
FLJMEES ET
dangereux
LES GAZ
peuvØnt
.
Le soudage gŁnŁre des fumŁes et des gaz. Leur
inhalation peut Œtre dangereux pour votre sante.
zones
de tomber.
Eloigner
UNIQUEMENT Si le
votre
tŒte des fumŁes. Ne pas respirer
les fumŁes.
Ølectrique savŁre nØces
lappareil en eat equipØ.
servir de Ia fonction de tØlecommande Si
Couper lalimentationou arrŒterle moteuravantde procØderlinstal
lation, a Ia reparation ou a lentretien de lappareil. DŁverrouiller
lalimentation selon a norme OSI-1A 29 CFR 191 0.147 (voir normes
de sŁcuritŁ).
lnstalleretmettre laterrecorrectement cetappareil conformØment
et aux codes nationaux, provinciaux et
son manuel dutilisation
municipaux.
Verifier et sassu
Toujours verifier Ia terre du cordon dalimentation
-
que le fil de terre du cordon dalimentation eat bien raccordŁ ala
borne de terre du sectionneur ou que lafiche du cordon est raccordŁe
a une prise correctement mise a Ia terre.
rer
En effectuant les raccordements dentrŁe fixer dabord
le conducteur
et contre-vŁrifler les connexions.
appropriŁ
frŁquemment le cordon dalimentation pour voir sil nest pas
endommage ou dŁnudŁ remplacer le cordon immØdiatement sil est
endommagŁ un cable dŁnudŁ peut provoquer une electrocution.
Mettre lappareil hors tension quand on ne lutilise pas.
Ne pas utiliser des cables uses, endommagØs, de grosseur insuffi
sante ou mal ØpissŁs.
de mise a Ia terre
piŁce,
soudure.
le demande.
source
contact avec Ia
tension.
Łlectrique
on
en
Fixer le cable de retour de facon a obtenir un bon contact mŁtal-mŁtal
avec Ia piŁce a souder ou Ia table de travail, le plus prŁs possible de a
Sisoler de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŁcher le contact phy
sique Łventuel avec Ia piŁce ou Ia terre.
courant
est
tuer.
Un simple contact avec des piŁces Ølectriques peut
provoquer une electrocution ou des blessures graves.
LØlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrØe et les
circuits internes de lappareil sont egalement sous
tension a ce moment-l. En soudage semi-automatique ou automatique,
le fil, le dØvidoir, le logement des galets dentrainement et les piŁces
mŁtalliques en contact avec le fil de soudage sont sous tension. Des
matØriels ma! installŁs ou mal mis a Ia terre prŁsentent un danger.
Ne
on
ace manuel.
Isoler Ia
ELECTRIQUE peut
quand
electrode provenant dune autre machine.
Nutiliser quun materiel en bon Øtat. RØparer ou remplacer sur-le
champ les piŁcesendommagØes. EntretenirlappareilconformŁment
avec
UN CHOC
Reportez-vousauxsymboles
etaux directives ci-dessous afin de connaitre les mesures a prendre pour
Łviter tout danger.
Verifier
zone et/ou utiliser un Łchappement au ni
de Iarc pour IŁvacuation des fumŁes et des gaz de soudage.
Si Ia ventilation est insuffisante, utiliser un respirateur a alimenta
tion dair homologuŁ.
A
IintØrieur, ventiler Ia
veau
Ure les specifications de sØcuritŁdes matØriaux (MSDS5) et les ins
tructions du fabricant concernant les mŁtaux, les consommables,
Inc.
ra~,atnrnontc
~,
Inc
,..
nOHn.,cntc at Inc danroiccn. .rc
.
~ ~
espace fermŁ seulement siI eat bien ventilØ ou
en portant un respirateur a alimentation dair. Demandertoujours a
un surveillant dOment formØ de se tenir a proximitŁ. Des fumŁes et
des gaz de soudage peuvent dØplacer lair et abaisser le niveau
doxygŁne provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration ne prŁsente aucun danger.
Travailler dans
un
Ne pas souderdans des endroits situŁs ~ proximitŁ dopØrations de
de nettoyage ou de pulvØrisation. La chaleur et les
rayons de Iarc peuvent rŁagir en presence de vapeurs et former
dŁgraissage,
des gaz hautement
toxiques
et irritants.
-
-
Ne pas enrouler les cables autour du corps.
Si Ia piŁce soudŁe dolt Œtre mise laterre, lefaire directement avec un
cable distinct
ne pas utiliser le connecteur de piŁce ou le cable de
Ne pas souder des mŁtaux munis dun revŒtement, tels que lacier
galvanisŁ, plaque en p10mb ou au cadmium a moms que le revŒte
ment nait ŁtŁ enlevØ dana Ia zone de soudure, que lendroit soft
bien ventilØ, et Si nŁcessaire, en portant un respirateur a alimenta
tion dair. Lea revŒtements et tous les mØtaux renfermant ces ŁlŁ
ments
peuvent dØgager des fumŁes toxiques
en cas
de
soudage.
-
retour.
OM-189 424
Page
5
I
LES RAYONS DE LARC
sur
des brlures
pendant
le
les yeux et
Ia peau
mŒmela
de larc du procØdØ de soudage
gØnre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
dans es yeux et sur a peau. Des Øtincelles soft projetØes
Le
.LES ~ACCUMULATIONS DE GAZ ris
quent de provoquer des blssures ou
peuvent pro
voquºrdes brlUres.dans
soudage.
.
.
.
Fermer lalimentation
non
Veiller
toujours a
rateur dadduction
Porter un casque de soudage muni dun Øcran de filtre appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49. 1 et Z87. 1 ØnumØrØ dans les normes de sØcuritØ).
Porter des
mon...
rayonnement
protections approuvØs
bien aØrer les espaces confines
dair homologue.
DES
pour les oreilles si le niveau sondre est
du gaz protecteur
cas
ou se
servir dun
PIECES:CHAUDES peuvent
voquer des brlures
trop ØlevØ.
en
de
utilisation.
respi
pro
graves..
.
Utiliser des Øcrans
ou
IØblouissement;
garder Iarc.
et de
des barriŁres pour protØger des tiers de Øclair
demander aux autres personnes de ne pas re
Ne pas toucher des
Porter des vŒtements de protection constituØ dans une matiŁre dura
au feu (cuir ou lame) et une protection des pieds.
PrØvoir
dutiliser
ble, resistant
m~I
~
LE SOUDAGE peUtprovoquer
incendie ou une explosion.
mains
personnes de Ia
le
pŁriode
pistolet
ou
de refroidissement avant
Ia torche.
MAGNETIQUES peuvent
LES CHAMPS
souda~e
Se protŁger et dautres
metal chaud.
une
un
effectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
provoquerleurØclatement. DesØtincelles peuventŒtre
projetØes de arc de soudure. La projection dØtincel
les, des piŁces chaudes et des Łquipements chauds peut provoquer des
incendies et des brlures. Le contact accidentel de lŁlectrode avec des
objets mØtalliques peut provoquer des Łtincelles, une explosion, Un
surchauffement ou un incendie. Avant de commencer le soudage,
verifier et sassurer que lendroit ne prØsente pas de danger.
Le
parties chaudes a
flues
projection dŁtincelles
affecter les stimulateurs
Porteurs de stimulateur
Les
cardiaque,
restez a distance.
porteurs dun stimulateur cardiaque doivent
dabord
consulter leur mØdecin avant de
operations de soudage a arc,
soudage par points.
des
de
cardiaques.
sapprocher
de gougeage
ou
et de
LE BRUIT
peut affecter l~ouIe.
Ne pas souder dans un endroit l ou des Øtincelles peuvent tomber
sur des substances inflammables.
Le bruit des processus et des
IouIe.
DØplacertoutes les substances inflammables a une distance del 0,7
m de arc de soudage. En cas dimpossibilitŁ
es recouvrirsoigneuse
ment avec des protections homologuŁs.
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
ment passer dans dautres
des ouvertures.
zones en
traversant de
SurveillertoutdŁclenchementdincendieettenir
un
Porter des
effectuØ sur un plafond, plancher,
peut dŁclencher un incendie de lautre ctØ.
soudage
extincteur
ou
proxi
Si des BOUTEILLES sont endomma
gØes, elles pourront exploser.
separation
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, elle peutexploser. Du faitque lea bouteilles degaz
font normalement partie du procØdØ de soudage, les
Ne pas effectuer le soudage sur des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtŁ prŁpa
rØs correctement conformØment a AWS F4.l (voir Ies normes de
sous
sØcuritØ).
Brancher le cable sur Ia piŁce le plus prŁs possible de Ia zone de sou
pour Øviter le transport du courant sur une Iongue distance par
des chemins inconnus Øventuels en provoquant des risques dŁlec
trocution et dincendie.
dage
Ne pas utiliser le poste de
lees.
En
de
soudage
pour
dØgeler
des conduites ge
utilisation, enlever Ia baguette dŁlectrode du portecouper le fil a Ia pointe de contact.
Porter des vŒtements de protection dØpourvus dhuile tels que des
gants en cuir, une chemise en matØriau lourd, des pantalons sans re
vers, des chaussures hautes et un couvre chef.
cas
electrode
non
ou
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
vos
poches
Le
tes. Pendant Ia
le passage de Ia piŁce
fil de fer, et le meulage gŁnŁrent
desØtincellesetdes particules mØtalliquesvolan
en
pØriode de refroidissement des soudures,
elles
risquent
de projeter du laitier.
Porter des lunettes de sØcuritØ
avec
Øcrans latØraux
precaution.
les bouteilles de gaz comprime dune chaleur excessive,
des chocs mØcaniques, du laitier, des flammes ouvertes, des Øtin
celles et des arcs.
Placer les bouteilles debout en lea fixant dans un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de
se renverser.
Tenir les bouteilles
cuits electriques.
Ne
jamais placer
ŁloignØes des circuits de soudage ou autres cir
une
Une electrode de
une
ou un
torche de
soudage
ne
soudage sur une bouteille a gaz.
jamais entrer en contact avec
doit
bouteille,
jamais
souder une bouteille
Ne pas tenir Ia tŒte
bouteille.
soudage, IØcaillement,
a Ia brosse
avec
ProtØger
pressurisee
-
risque dexplosion,
Utiliser seulement des bouteilles de gaz protecteur, rŁgulateurs,
tuyaux et raccords convenables pour cette application spØcifique;
es maintenir ainsi que les ØlØments associØs en bon Øtat.
peuvent blesser les yeux.
S
manipuler
Ne
DES PARTICULES VOLANTES
~
les oreilles Si
fissures et
petites
paroi
protections approuvØs pour
trop ØlevØ.
affecter
le niveau sondre eat
mite.
Le
equipements peut
en
face de Ia sortie
en
ouvrant Ia soupape de
Maintenir le chapeau de protection sur Ia soupape, sauf
dutilisation ou de branchement de Ia bouteille.
Lire et suivre
a
en cas
instructions concernant lea bouteilles de gaz corn
et les publications P-i CGA enu
merees dana lea normes de sØcuritØ.
prime,
les
es
Øquipements associØs
Øcran facial.
.
OM-189 424
Page
6
1-3.
Dangers supplØmentaires
en
relation
avec
IinstaLlation, le fonctionnement
ella maintenance
DES ORGANES MOBILES
DINCENDIE OU
DEXPLOSION.
Risque
Ne pas
placer lappareil
proximitØ
Ne pas installer
Iappareil
sur,
au-dessus
ou
a
Rester a lØcart
de surfaces infllammables.
a
proximitØ
de
Maintenir fermØs et fixement
inflammables
produits
panneaux,
-
en
le
comme
en
et
recouvrements
place los portes,
dispositifs de
protection.
service.
LACHUTE DE LAPPAREIL
des organes mobiles
ventilateur.
Ne pas surcharger linstallation Ølectrique sassurer que lalimen
tation est correctement dimensionnØ et protØgØ avant de mettre
lappareil
pevent
provoquer des blessures.
LE RAVONNEMENT HAUTE FRE
QUENCE (H.F.) risque de provoquer
des interferences.
peut
blesser.
Le rayonnement hautefrequence peut provoquer
des interferences avec les Øquipements de ra
dio-navigation etde communication, les services
de sØcuritØ et los ordinateurs.
Utiliser lanneau de levage uniquement pour sou
lever lappareil, NON PAS les chariot, les bouteil
es
de gaz
ou tout autre
Utiliser un engin dune
soulever lappareil.
accessoire.
capacitØ appropriØe
pour
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que les fourches sont suffisamment longues pour dØpasser du ctØ
oppose
de
Demander seulement a des personnes qualifiØes familiarisØes
des Øquipements Ølectroniques de faire fonctionner linstalla
tion.
avec
lappareil.
Lutilisateur est tenu do faire corriger rapidement par
los interferences resultant de linstallation.
un
Ølectricien
qualifie
Silo FCC
signale des interferences, arrŒter immØdiatement lappa
reil.
LEMPLOJ EXCESSIF petit
SURCHAUFFER LEQI.JIPEMENt
PrØvoir
ter le
une
pØriode
do refroidissement, respec
Effectuer
rØguliŁrement
le contrle
et lentretion
de installation.
Maintenir soigneusement fermØs les portes et les panneaux des
sources do haute frØquence, maintenir lea Łclateurs a une distance
correcte et utiliser une terre ot et un blindago pour rØduire los inter
fŁrences Øventuolles.
cycle opØratoire nominal.
RØduire le courantou lecycleopØratoireavantde
recommancer le soudage.
Ne pas obstruer los passages dair
du
LES CHARGES
A LARC risque de
interferences.
des
provoquer
LE
poste.
ELECTROSTATIQUES
peuvent endommager
SOUDAGE
LØnergie
ØlectromagnØtique
risque
do
provoquer des interferences pour lŁquipomont
Ølectronique sensible tel que los ordinateurs et
lØquipement commandŁ par ordinatour tel quo
les circuits im
primes.
les robots.
Etablir
connexion avec Ia barrette de terre
avant de manipuler des cartes ou des piŁces.
a
Utiliser des
pochettes et des boltes antistatiques
pour stocker, dØplacerou
circuits imprimes.
expØdierdes cartes de
DES
ORGANES MOBILES
provoquer des blessures.
Ne pas
sapprocher
pevent
des organes mobiles.
Ne pas sapprocher des points de coincement
tels quo des rouleaux de commande.
lŁquipement do Ia zone do soudage soit com
patible electromagnØtiquement.
Pour rØduiro Ia possibilitØ dinterfŁrerice, maintenir los cables de
soudage aussi courts quo possible, los grouper, et los poser aussi
bas quo possible (ox. par terre).
Voiller a souder a une distance de 100 metres de tout Øquipement
electronique sensible.
Veiller a ce quo ce poste de soudage salt pose et mis a Ia terre
conformØment a ce mode demploi.
En cas dinterfØrences aprŁs avoir pris los mesures prØcØdentes, il
incombe a lutilisateur do prendre des mesures supplØmontaires
telles que lo dØplacement du paste, lutilisation do cables blindØs,
lutilisation do filtres de ligno ou a pose do protocteurs dans Ia zone
Veiller ace que tout
de travail.
LES CHAMPS
LES FILS DE SOUDAGE peuvent pro
voquer des blessures.
MAGNETIQUES peuvent
affecter les stimulateurs
Porteurs de stimutateur
avant den avoir
tance.
pistolet vers soi, dautres per
ou toute piŁce mŁcanique en engageant
soudage.
dabord
Ne pas appuyer sur Ia
recu linstruction.
Ne pas
sonnes
le fil de
diriger
le
gachette
cardiaques.
cardiaque,
rostez a dis
Les porteurs dun stimulateur cardiaque doivent
consultor leur mŁdecin avant do sappro
cher des operations do soudage a larc, do gou
geage ou do soudage par points.
OM-189 424
Page
7
1-4
Principa~es
normes
de securitØ
Safety in Welding and Cutting, norme ANSI Z49.1 delAmericanWel
ding Society, 550 NW. Lejeune Rd, Miami FL 33126
,
Safe
P-i,
way,
Safety and Health Sandards,
OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cut
ting of Containers That Have Held Hazardous Substances, norme
AWS F4.1 de lAmerican Welding Society, 550 NW. Lejeune Rd, Mia
,
mi FL 33126
1 -5~
Information
sur
les
coupage etprocØdØs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, RexdaJe (Ontario) Canada M9W
1R3.
me
Safe Practices ForOccupationAndEducational EyeAnd Face Protec
tion,
sure soudage Ølectrique et sur les effets,
champs magnØtiques basse frØquence
pour
lorganisme,
Afin de rØduire les
de
soudage, pendant son passage dans les cables de sou
dage, causera des champs electromagnetiques. II y a eu et II y a
encore un certain souci a propos de tels champs. Cependant, aprØs
avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pe
node de recherche de 17 ans, un comitØ special ruban bleu du
National Research Council
jugement
du
a
comitØ,
conclu: Laccumulation
na
Fire
pas dØmontrØ que lexposition aux
Ølectriques a haute frØquence reprØ
champs ØlectromagnØtiques dans lenvironnement
travail, respecter les consignes suivantes
1
Garder les cables ensembles en les torsadant
attachant avec du ruban adhØsif.
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
votre corps.
4
de preuves, sui
champs magnØtiques et champs
sente un risque a Ia sante humaine.
Toutefois, des etudes sont
toujours en cours et les preuves continuent a Łtre examinØes. En at
tendant que es conclusions finales de Ia recherche soient Øtablies, il
vous serait souhaitable de rØduire votre exposition aux champs Ølec
tromagnØtiques pendant le soudage ou le coupage.
OM-189 424 Page 8
ANSI Z87.1, de lAmerican National Standards Institute,
New York, NY 10018.
Broadway,
Cutting and Welding Processes, norme NFPA 51 B, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
Le courant de
vant le
norme
champs ØlectromagnØtlques
DonnØes
des
Regles de sØcuritØ en soudage,
1430
National Electrical Code, NFPA Standard 70, de Ia National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
Handling of Compressed Gases in Cylinders, CGA Pamphlet
Compressed Gas Association, 1235 Jefferson Davis High
Suite 501, Arlington, VA 22202.
de Ia
Garder le poste de
de
5
ne
oppose
de
les
ou en
IopØrateur.
pas entourer pas les cables autour de
soudage
et les cables le
plus
loin
possible
vous.
Relier Ia
pince
de
masse
le
plus prŁs possible
de Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous Œtes dØclarØ apte par votre docteur, il
est alors recommandØ de
respecter les consignes ci-dessus.
.
SECTION 2- INSTALLATION
Specifications
2-1.
Max.
Rated
Output
300 A at 32
240 A at 32
VDC,
60%
Duty Cycle
Wire
Type
100%
VDC,
Amps Input
Open
Voltage
at Rated
230 V
400 V
38
44.4
25.5
Wire Feed
(0.6
-
I Stainless Steel
-
2-2.
1/16 in
1.6
.023
mm)
(0.6
Duty Cycle
.035 in
-
-
0.9
And
I
pr,1
j
or
60 Hz
l~
KVA
12.7
17.9
50-670 1PM
Flux Cored
mm)
.030
(0.8
-
-
1/16 in
1.6
Weight
Dimensions
Net
H: 37 in
W: 19 in
275 lb
Speed
(1.2-1.7 rn/mm)
.023
50
Duty Cycle
and Diameter
Solid Steel
Output,
Circuit
D:
(940 mm)
(483 mm)
30-1/4 in (768 mm)
(125 kg)
mm)
Overheating
is
Duty Cycle
500
percentage of 10
minutes that unit
~
load without
~3
300
0..
-
-
-
-
0
z
-
weld at rated
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
s
~250
can
overheating.
-
-
welding.
~
A
~
100
-
10
15
~
~
40
30
-
Exceeding duty cycle
damage unit and
warranty.
can
void
-
5060708090100
%DU1YCYCLE
60%
Duty Cycle
At 300
100%
Amperes
At 240
Amperes
i~
g
6 Minutes
Duty Cycle
Welding
4 Minutes
Continuous
Resting
Welding
Overheating
r~
15
to; ~i
L~i
)
~
OR
Reduce
~)~~~1
Duty Cycle
Minutes
sdutyi 5/95 /SA-i 87 478-A
OM-189 424
Page
9
2-3.
Volt-Ampere Curve
1
Normal
The
volt-ampere
normal
Volt-Ampere Curves
curves
minimum and
show the
maximum
voltage and amperage output ca
pabilities of the welding power
source. Curves of other settings
fall between the
curves
shown.
40
2
Overload
Volt-Ampere
Curves
When unit is used
ity, circuitry
beyond capac
senses
the overload
and shuts down unit
output. Re
lease
H
trigger and lower weld volt
age setting before trying to weld.
This shut down circuitry protects
20
internal
circuits
overload
damage.
and
parts from
0
0
~J
tIJ
15~J
2tJJ
25J
33J
3~O
4W
LU A~vFEF~IS
ST-i 89 478
.
2-4.
Installing
Work
Clamp
.
OM-189 424
Page
10
2-5.
Installing Welding Gun (Gun
2-6.
Setting Gun Polarity
Not
For Wire
Included)
Type
1
Shipped Set For Electrode
Positive (DCEP) For Solid Steel Or
Aluminum Wires (GMAW Process).
Shown As
-
Polarity Changeover
(Located Near Drive
Assembly)
Always
tures
Label
-
read and follow manufac
recommended
polarity.
Wire Drive
To Positive
Assembly Lead
(+) Output Terminal
Work Clamp Lead To
Negative (-) Output Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
For Electrode
Reverse Lead Connections
Negative (DCEN) For Flux Cored Wires
-
(FCAW Process). Drive Assembly
Negative
S1~~9-D
Becomes
~====r
3/4, 11/16 in
OM-189 424
Page
11
2-7.
Remote 14
Receptacle
REMOTE 14
Socket Information
Socket*
0
-
f~
~
Protected
A
24 volts
B
Contact closure to A
circuit.
G
Circuit
ac.
by
circuit breaker CB2.
OUTPUT
(cONTACTOR)
010
completes
24 volts
ac
contactor control
FEEDER
common
for 24 and 115 volts
ac
circuits.
Ref. ST-152 973-A
*The
2-8.
remaining
sockets
are
not used.
Installing Gas Supply
Chain gas
wall,
or
cylinder to running gear,
stationary support so
other
cylinder
cannot fall and break off
valve.
NOTE: All items listed below
customer
1
Regulator/Flow Gauge
Install
2
are
supplied.
so
face is vertical.
Gas Hose Connection
Obtain and connect gas hose of
proper size between regulator and
rear of machine.
Note: it may be necessary to install
Argon Gas
supplied barbed Euro-adapter, into
gas fitting on rear of machine, be
fore connecting gas hose.
3
OR
Flow
Adjust
flow rate is .57 cmh (cubic
meters per hour). Check wire man
flow
ufacturers
recommended
Typical
rate.
3
4
CO2 Adapter
5
0-Ring
adapter with 0-ring between
regulator/flow gauge and CO2
Install
cylinder.
Ref. ST-i 48 265-B / Ref. ST-i 49 827-B I Ref. ST-i 58
OM-189 424
Page
12
2-9.
Installing
Wire
Spool
and
Adjusting Hub
Tension
OM-189 424
Page
13
2-10. Inductance Selection
Remove left side
panel.
Stabilizer Z
1
Tapped
stabilizer Z is
factory
nected to the stabilizer
suits most GMAW
Tools Needed:
con
tap which
applications.
Stabilizer Z controls the induc
tance applied to the weld current.
To increase inductance and wet
3/8,7/16 in
out the weld
3/8 in
stabilizer Z
To
change
connect to
puddle,
ending.
inductance
proceed
as
follows:
2
Lead 24
3
Stabilizer Z
Tap
4
Stabilizer Z
Ending
5
Lead 25
To decrease
inductance,
tap
lead 25 to stabilizer
connect
and
se
cure.
Reinstall side
6
panel.
Typical Weld Bead Using The
Tap Stabilizer Connection
Use the
tap Stabilizer connection
when
welding
shielding gas.
with
100%
CO2
Use either stabilizer connection,
depending upon your arc prefer
ence, while welding with a mixed
shielding gas.
Use stabilizer Z
stainless steel.
7
ending
to weld on
Typical Weld Bead Using
End High Stabilizer
The
Connection
Use the end Stabilizer connection
to reduce weld bead crowning, and
spread
the weld
Install left side
7
lj~
Weld Bead Using The Tap Stabilizer
Connection With 17 Volts, 100 Amps
puddle.
panel.
Weld Bead
Using The End Stabilizer
Connection With 17 Volts, 100 Amps
Rel. ST-148 265-B/ Ref. ST-801 379-B
2-11. Electrical Service Guide
Input Voltage
Input Amperes
At Rated
Output
Max Recommended Standard Fuse Or Circuit Breaker
In Amperes
Mm
Input Conductor Size
Max Recommended
Mm
Grounding
In AWG/Kcmil
Input Conductor Length
Page
In Feet
Conductor Size In AWGfKcmiI
Reference: 1996 National Electrical Code (NEC)
OM-189 424
14
Rating
(Meters)
230
400
44.4
25.5
70
40
8
10
128
8
(39)
259
10
(79)
2-12.
Selecting
a
Location and
Connecting Input
Power
Tools Needed:
r 3/8 in
c:::::z1===tl
3/8 in
GND/PE
GND/PE
Connect First
Size and ratings must comply with applicable
codes (see Section 2-11). Install conductors
in conduit
or
equivalent
into
a
deenergized
line disconnect device.
Do not
jumper
overtighten
link nuts.
400 VOLTS
230
VOLTS\
i~
H
~oooooo
I S94 II
Ret. ST-801 768
Have
1
only qualified
Rating
Check
persons make this installation.
Jumper
Move
Label
input voltage
3
available at site.
Remove wrapper.
Links
jumper
links to match
input voltage.
Reinstall wrapper.
A
Special installation may be required where gasoline
volatile liquids are present
see NEC Article 511 or
or
-
2
Jumper
Link Label
CEC Section 20.
OM-189 424
Page
15
2-13.
Threading Welding
Wire
1
Wire
2
Welding
3
Inlet Wire Guide
4
Pressure
5
Drive Roll
6
Outlet Wire Guide
7
Gun Conduit Cable
Lay gun
Spool
Wire
Adjustment
cable out
Knob
straight.
Tools Needed:
Open pressure assembly.
Pull and hold
wire;
cut oft end.
Push wire thru
guides
into gun;
continue to hold wire.
-,
Close and
assembly,
tighten pressure
Remove gun nozzle and contact
tip.
and let go of wire.
1111
II
)
Press gun
trigger
until wire
of gun. Reinstall
contact tip and nozzle
comes out
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Tighten
Cut oft wire. Close
and latch door.
Ref. 5T~8O1 770/ S-0627-A
OM-189 424
Page
16
.
SECTION 3- OPERATION
3-1.
Controls
OM-189 424
Page
17
SECTION 4
4-1.
MAINTENANCE &TROUBLESHOQTING
Routine Maintenance
~
F!
A
I
~
Disconnect power
before
maintaining,
Maintain
during
more
severe
often
conditions.
I
.
4-2.
Circuit Breaker CB1
1
Circuit Breaker CB1
If CB1 opens, wire
2
Welding
Gun
feeding stops.
(Not Included)
Check gun liner for
blockage
or
kinks.
3
Wire Drive
Assembly
Check for
jammed wire, binding
drive gear or misaligned drive rolls.
2
Allow
cooling period
and
reset
breaker. Close door.
Ref. 5T-801 770
4-3.
Unit Overload
If unit is used
trigger
beyond capacity (excessive wire feed,
to reset this condition.
OM-189 424
Page
18
shorted output,
etc.),
wire feeds but is not
energized. Release gun
4-4.
Changing
Drive Roll and Wire Inlet Guide
NOTE: Drive rolls and inlet wire
not included. See
are
guide
ordering
Table 6-1 for
informa
tion.
Screw
1
Securing
2
Inlet Wire Guide
Slide
tip as
possible
touching. Tighten screw.
Loosen
drive
3
as
close to
without
Anti-Wear Guide
Install
4
screw.
rolls
guide
as
shown.
Drive Roll
Install correct drive roll for wire size
and
type.
5
Drive Roll
Turn nut
one
Securing
click to
Nut
secure
drive
roll.
Tools Needed:
5/64 in
I~ 7/161n
4-5.
Aligning
Drive Rolls and Wire Guide
A
Turn Off power.
View is from top of drive rolls look
ing down with pressure assembly
open.
Correct
Incorrect
5
1
Drive Roll
2
Drive Roll
3
Wire Guide
4
Welding
5
Drive Gear
Securing
Nut
Wire
Insert screwdriver, and turn screw
or out until drive roll groove lines
in
up with wire
guide.
Close pressure roll
assembly.
+
Tools Needed:
Ref. ST-800 412-A
OM-189 424
Page
19
4-6.
Troubleshooting
F1I~1r~
Trouble
Remedy
No weld output; wire does not feed.
Be
sure
line disconnect switch is On
line fuse
Replace building
Reset circuit breaker CB1
Secure gun
No weld
output;
wire feeds.
trigger
(see Section 2-12).
reset circuit breaker if open
or
(see
Section
connections
(see
4-2).
Section 2-5, and
Agent
check Power switch.
Have
Factory
Authorized Service
Agent
check all board connections and main control board.
Thermostat TP1 open
(see Section 2-2).
Have
clamp
contact
(overheating). Allowfan to run;
to
Check
Low, high,
or
Authorized Service
Factory
Manual).
erratic wire
speed.
trigger (see
4-3).
check main control board and main rectifier.
check for low line
or
Section
links and correct
position
voltage (see
if necessary
Factory
Authorized Service
Agent
check main control board.
Have
Factory
Authorized Service
Agent
check fan-on-demand circuit.
Readjust
drive roll pressure
inlet
Replace
Have
panel settings (see
to correct size drive rolls
Readjust
Check
front
guide,
position
Factory
of
contact
Turn Wire
links
Authorized Service
Speed
(see
control to
Readjust
Change
drive roll pressure
Check gun
Have
trigger
Factory
Wil ~
Agent
tip
(see
or
Section
Manual).
2-12).
4-2).
Section
Section
3-1).
(see gun Owners
Manual).
2-13).
(see Section 4-4).
Repair
Authorized Service
(see gun Owners
check main control board.
liner
~ I
and leads.
4-4).
2-13).
higher setting (see
to correct size drive rolls
W~IUjI
(see
Section
Clear obstruction in gun contact
.
liner if necessary
tip, and/or
2-12).
3-1).
Section
(see
Section
(see
input jumper
Reset circuit breaker CB1
Section
Section
(see Section 2-12).
Have
Change
No wire feed.
Agent
input voltage
input voltage jumper
the thermostat will close when the unit has cooled
metal to metal contact.
get good
tip (see gun Owners
Connect unit to proper
run.
Manual).
Authorized Service
An overload condition occurred. Release gun
Fan motor does not
gun Owners
Factory
Replace
output.
see
Have
Connect work
Low weld
(see Section 2-12).
I
or
Agent
replace gun
if necessary
(see gun Owners
Manual).
check main control board.
S
OM-189 424
Page
20
SECTION 5- ELECTRICAL DIAGRAM
SD-i 89 410
Figure
5-1. Circuit
Diagram
OM-189 424
Page
21
SECTION 6- PARTS LIST
~ET Hardware is
common
and
not available unless listed.
0)
c~J
L()
/
CD
CD
/
U-
/
/
LU
N
N
CD
CD
/~
0)
U-
/
(0
ST-802 104
Figure
OM-189 424
Page
22
6-1. Main
Assembly
Dia.
Item
No.
Part
No.
Mkgs.
Figure
1
..
PLG8
008 072
..
2
3
Fig
....
Ti
TP2
6-2
...
189 414
...
163 266
4
Fig
6-6
5
146 165
6
089 899
7
+146 167
8
134 464
Quantity
Description
...
...
..
.
.
.
.
...
...
...
...
...
6-1. Main
Assembly
HOUSING RECEPTACLE & SOCKETS
1
BAFFLE, center w/components
TRANSFORMER, pwr main
THERMOSTAT, NO
PANEL, rear w/components
PANEL, side LH
LATCH, slide flush mtg hole 1.000 wide
PANEL, side
LABEL, warning general precautionary
1
1
1
1
1
x
1.500
2
Ig
1
1
+170513...WRAPPER
9
CABLE, pwr
10
187 804
..
11
185541
...
12
186758...WHEEL
13
052 692
.
1
1 2ft
8ga 4/c
1
BASE
1
2
AXLE, running gear (consisting of)
RING, retaining ext .750 shaft x .O8Sgrv depth
185 555
RECTIFIER, SCR main (consisting of)
031 689
CAPACITOR, rectifier
185 830.... THYRISTOR, SCR 568A 400V
171 600.... THERMOSTAT, NC
..
1
.
121 614....
14... SRi
...
C7-12
D4-6
D7,8
115 093
..
185 831
..
..
15
17.... Zi
...
3
1
CONNECTOR & SOCKETS
1
DIODE, rect 450A 200V
DIODE, rect 275A 300V
CASTER, plstc swvl 4 in dia
PANEL, front w/components
3
STABILIZER
1
....
....
008 999
...
6-4
...
187 998
...
130 750
...
600 320
+When
....
037 956
Fig
16
6
....
.
...
PLG2
1
...
..
SCR1-3
TP3
2
...
CLAMP, ground 350A
CABLE, weld cop strd No.
2
2
1
1
1
1 Oft
(order by ft)
a precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
ordering
a
component originally displaying
To maintain the
OM-189 424
Page
23
Hardware is
common
and
not available unless listed.
/
/
0
(0
0)
U)
0
(0
CJ
C,)
C~J
C
C
C
U)
(0
a)
U-
ST-BOi 952-A
Figure
OM-189 424 Page 24
6-2.
Baffle, Center w/Components
2
1
....
Item
No.
Dia.
Part
No
Mkgs.
Description
Figure
058 427
...2
085 980
605 941
186 437
057 971
...6
057 745
...
...
.
.
.
...
.
.
.
...
6-2.
Quantity
Baffle, Center w/Components (Fig 6-1 Item 2)
RING, retaining spool
NUT, stl hex full .625-11
WASHER, flat stl .640 ID x 1.000 OD x l4gathk
SPRING, cprsn .845 OD x .110 wire x 1.500
WASHER, flat stl keyed 1 .500dia x .l25thk
SPRING, cprsn 2.430 OD x .090 wire x 2.500
1
1
186435...HUB,spool
WASHER, brake
REEL, support
188 710
BAFFLE, center, (consisting of)
184 965
COVER, primary board hole
11
CAPACITOR ASSEMBLY KIT, (consisting of)
186 998
082 902
STRIP, mtg center capacitor
185 643
STRIP, mtg capacitors
083 147.... GROMMET, scr No. 8/10 panel hole .312sq .500 high
184 584.... CAPACITOR, elctlt 1 S000uf 45VDC
187752
INSULATOR, capacitor
TEl
TERMINAL ASSEMBLY, pri 3ph two voltage
15
189 409
038 618
LINK, jumper term bd pri
...17...PC1 184 331
CIRCUIT CARD, control main
...8
186 436
..
177 307
...
1
.
...
....
1
...
....
....
....8
....
.
.
1
.
3
...
1
...
PLG3 131 052
PLG4.. 131 056
PLG6.. 115 092
119 998
...
...
...
...
C3,5
128 750
...20... NEG
097 416
.
.
.
...21...POS
097 421
.
.
.
...19...
185 850
..
.
...
141567...
129 524
071 971
25.CB1,CB2
.26
ordering
a
.
.
...
180 912
...
134 201
...
Fig
+When
.
6-5
..
.
HOUSING RECEPTACLE & SOCKETS
HOUSING RECEPTACLE & SOCKETS
HOUSING PLUG & SOCKETS
RESISTOR, WW fxd 300W
1
1
1
5 ohm
1
CAPACITOR
2
TERMINAL, pwr output black
TERMINAL, pwr output red
BUSS BAR, shunt
SHUNT, meter 50V400A
TERMINAL, frict male .250 x .032 3 pair
COVER, cable
CIRCUIT BREAKER, man reset 1P 5A25OVAC
STAND-OFF SUPPORT, PC card
1
1
1
1
1
1
2
4
WIRE DRIVE & GEARS
component originally displaying
a
precautionary label,
1
the label should also be ordered.
To maintain the factory original pertormance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 89 424
Page
25
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
...4....C2
5..
C13-15...
...6
035 897
POTENTIOMETER
2
185 890
LEAD ASSEMBLY, elect
LEAD ASSEMBLY, elect
1
CAPACITOR, cer disc .OO3uf 2000VAC
PANEL, front
SWITCH, tgl 3PST 40A 600VAC
3
RECEPTACLE w/SOCKETS
RECEPTACLE w/SOCKETS
1
PANEL, logo
PANEL, louver
LIGHT, md white lens 28V
KNOB, pointer 1 .625dia x .250 ID
1
185 896
148 240
048 282
143 976
10
186 470
11
186 472
157 958
097 924
common
16)
1
186 473
Hardware is
6-1 Item
PANEL, front control
LABEL, nameplate
128 756
...12....PL1....
Panel, Front w/Components (Fig
189 350
+188 711
...2....R2,3....
6-3.
Quantity
..
1
1
1
1
1
1
1
2
and
not available unless listed.
13
12
11
ST-801 953
Figure
6-3.
Panel, Front w/Components
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 424
Page
26
Item
No.
Dia.
Mkgs.
Part
No.
Quarmty
Description
Figure
6-4. Wire Drive And Gears
(Fig
6-2 Item
27)
1
602009
1
2
172075
166072
1
SCREW, .250-20 x 1.25 soc hd gr 8
CARRIER, drive roll w/components
3
SPACER, gear
4
010224
PIN, spring CS .187 x 1.000
182 788
HOUSING, adapter gun/feeder
085 242
FASTENER, pinned
085 244
WASHER, cupped stl .328 ID x .812 OD x .125 lip
.010231
SPRING, cprsn .770 OD x .105 wirex 1.225
085 243
KNOB, adj tension
166 071
LEVER, mtg pressure gear
11
079 634
PIN, hinge
.151828... PIN, cotter hair .054x.750
173 616
COVER, right angle motor
...14...PM.. 173 435
MOTOR, gear 24VDC 122RPM 20:1 ratio
079 633
FITTING, hose brs barbed M 3/l6tbg
.601 966
SCREW, .375-16x 1.25hexhd
145 237
STOP, cover
604 538
WASHER, flat stl SAE .312
124 778
KNOB, plstc T 1.000 lg x .312-18 x 2.000 bar
173 619
CARRIER, drive roll w/components
.174609...SCREW,M4-.7x12
...22
.174610... SCREW,M6-1.Ox20sochd
...23
173 620
BUSHING, motor mtg
*045 233
GUIDE, anti-wear
1
1
...
...
.
.
.
1
...
1
...
1
...
1
...
2
1
...
1
...
1
...
3
...
1
...
.
.
1
.
1
...
1
...
1
3
3
...
1
...
OT Hardware is
common
and
not available unless listed.
9
See Table 6-1 For
Drive Roll & Wire Guide Kits.
4
16
17
19~
18
Figure
*Recommended
Spare
ST-148 529-C
6-4. Wire Drive And Gears
Parts.
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 424
Page
27
Table 6-1. Drive Roll And Wire Guide Kits
Note~
Base selection of drive rolls upon the
following
recommended usages:
1
V-Grooved rolls for hard wire.
2
U-Grooved rolls for soft and soft shelled cored wires.
rolls for
extremely soft
3
U-Cogged
4
V-Knurled rolls for hard shelled cored wires.
5
Drive roll
with
types may
U-Grooved).
shelled wires
be mixed to suit
(usually
hard
surfacing types).
particular requirements (example:
Wire Diameter
V-Knurled roll in combination
Drive Roll
Inlet
Wire Guide
Kit No.
Fraction
Decimal
Metric
.023/025 in.
.023/025 in.
0.6mm
.030 in.
.030 in.
0.8
.035 in.
.035 in.
.045 in.
.045 in.
.052 in.
1/16 in.
Part No.
Type
087 131
087 130
V-Grooved
056 192
mm
079 594
053 695
V-Grooved
056 192
0.9
mm
079 595
053 700
V-Grooved
056 192
1.2
mm
079 596
053 697
V-Grooved
056 193
.052
1.3mm
079 597
053 698
V-Grooved
056 193
.062
1.6mm
079 598
053 699
V-Grooved
056 195
Ret. S-0026-B/7-91
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
049 399
148 809
...FM1... 148 808
6-5.
Quantity
Panel, Rear w/Components (Fig
NUT, speed push-on-type .312 stud .625 OD
BLADE, fan 9 in 5wg 34deg .309 bore CCW
MOTOR, fan 230V 1550RPM .3l2dia shaft
x
6-1 Item
4)
.4 56 ID
.188709 ...WINDTUNNEL
...GS1..
.6
125785
143810
169654
602 387
605 227
10
178 126
VALVE, 24VAC 2 way custom port 1/8 orf
PANEL, rear
BRACKET, support tank
CHAIN, weldless 2/0 x 27.000 Ig
NUT, nyl hex jam .75ONPST
CONNECTOR, clamp cable .690/1.070
1
.
1
1
1
1
lET Hardware is common and
not available unless listed.
~Y8
p
I~
ST-801 954-A
Figure
6-5.
Panel, Rear w/Components
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 424
Page
28
Effective January 1, 1990
(Equipment with a serlai numher preface of it
Warranty
Questions?~
¶7
LIMITED WARRANTY
below, Miller Electric
warrants to its original
is free of detects in material and
OF
ALL
you.
Service:.
Support
H
EXPRESS
WARRANTIES
OR
Remote Controls
*
Accessory
*
Replacement
*
Spoolmate
OF
writing within thirty (30) days
of such detect
failure, at which time Miller will provide instructions
warranty claim procedures to be followed.
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.
apply
to:
by Miller, but manufactured by others,
engines or trade accessories. These items are
covered by the manufacturers warranty, if any.
such
as
Consumable
2.
such
components;
as
contact
tips, cutting
or
parts
wear.
that has been modified by any party other
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
Equipment
3.
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
than
International distributor.
which
has
been used
specifications
5 Years Parts
shall not
Items furnished
1.
that fail due to normal
1.
Warranty
nozzles, contactors, brushes, slip rings, relays
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
an
(No labor)
Parts
185
or
the
on
Kits
True Bluefi Limited
Millers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such dafects in material or workmanship. Miller must be
notified in
other
warranty
at the time it is
WARRANTIES,
INCLUDING
no
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
*
lime
Need fast
.
OTHER
THE
MERCHANTABILITY AND FITNESS.
Your distiibutor also gives
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
workmanship
with
Torches
Miller. THIS WARRANTY IS EXPRESSLY IN
shipped by
IMPLIED,
:YouaIwaysgetthetast~
after the effective date of this limited
equipment sold
*
Subject to theterms and conditions
Mfg. Co., Appleton, Wisconsin,
retail purchaser that new Miller
-
LIEU
H
warranty supersedes all previous Miller warranties and is exclusive
guarantees or warranties expressed or implied.
This limited
Call.
1 -80041-MILLER
lor.OUr SI
Miller distributor
newer)
or
for the
for operation
equipment.
outside ot the
3 Years Labor
-
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
*
*
main power rectifiers
Original
Inverters
(input
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
output rectifiers only)
and
AND MAINTENANCE OF WELDING EQUIPMENT.
2.
Parts and Labor
3 Years
In the event of
*
3.
Transformer/Rectifier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
*
Intellitig
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
engine manufacturer.)
Power Sources
Culling
Supplies
the
Parts and Labor
t Year
a
warranty claim covered by this warranty,
the
exclusive remedies shall be, at Millers 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 customers risk and expense. Millers option of
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed
*
Motor Driven Guns
*
Process Controllers
*
Positioners and Controllers
(w/exception
of
Spoolmate 185)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
IN NO EVENT SHALL MILLER BE LIABLE
INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
REMEDIES.
FOR
*
Automatic Motion Devices
*
Robots
*
IHPS Power Sources
*
Water Coolant
DIRECT,
PROFIT),
WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
NOT PROVIDED HEREIN
ANY EXPRESS WARRANTY
4
.
HF Units
*
Grids
*
Spot Welders
*
Load Banks
*
SDX Transformers
*
Miller
*
Running Gear/Trailers
*
Plasma
IMPLIED
WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
AND
V//A Miller
TlielbwerofB&
ZIPCUT &
Deutz
Options
(NOTE: Field options are covered under True Bluefi
forthe remaining warranty period of the product they
4.
6 Months
5.
90
*
North
America)
Field
installed
Days
in,
or
for
a
greater.)
Batteries
Pans and Labor
MIG Guns/TIG Torches
BUT
BY
FOR
THIS
IMPLICATION,
minimum of
one
Some states in the U.S.A. do not allow limitations ot how long
implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
an
*
are
ARISE
AND DISCLAIMED BY MILLER.
Cutting Torches (except APT,
PLAZCUT Models)
Engines (outside
WHICH,
THEORY
MIGHT
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
Cyclomatic Equipment
whichever is
LEGAL
PROVISION,
*
--
ANY
OTHER
:
.
~N
Systems
*
year
or exclusion may not apply
provides specific legat rights, and
limitation
available, but may vary from
In
Canada, legislation
in
to you. This
other
rights
warranty
may
be
state to state.
some
provinces provides
for certain
stated
may not be waived, the
not
limitations and exclusions set out above may
apply. This
Limited Warranty provides specific legal rights, and other
additional
warranties
or
remedies
herein, and
to the extent that
rights may
province.
be available,
other than
as
they
but may vary from
province
miller
warr
to
iiae
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date
which equipment
delivered to
was
original customer.)
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor fop:
To locate distributor nearest you call
1-800-4-A-Miller.
Welding Supplies
Options
and Consumables
and Accessories
Personal
Safety Equipment
Service and
Repair
Replacement
MullerElectncMfg
An lltrtois Tool Works
Parts
1635 West
Appleton
Training (Schools, Videos, Books)
Spencer
Co
Company
Street
WI 54914 USA
Internatinal Headquarters-USA:
M~ni I~lQ (~~r~,itinn
T~,hnir.c~l
and
Infnrmotir~n
nv......
nfl!,
,nc
.:
.ICfl~
-
USA &Canada FAX 920-735-4134
Parts)
lntemalionat FAX 920-735-4125
Circuit
Diagrams
Welding
European Headquarters
United Kingdom
Phone: 44 (0)1204-593493
-
Process Handbooks
FAX: 44
(0)1204-598066
www.MffletWelds.com
Cuntact the Delivering Carrierfor:
File
a
claim for loss
or
damage during
shipment.
For assistance in
filing
contact your distributor
manufacturers
settling claims,
and/or equipment
or
Transportation Department.
p//A Miller.
The Power
PRtNTED tN USA
'
1998 Muter Etectric
Mig. Co. 5/98
...
--
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