Miller | LE394757 | Owner Manual | Miller PIPEPRO 450 RFC CE User manual

Miller PIPEPRO 450 RFC CE User manual
OM-223 586B
February 2005
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
™
PipePro 450 RFC
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Equipment Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Rear Panel Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Motor Control Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Front Panel Controls (See Section 5-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Front Panel Controls - Continued (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4
5
5
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9
9
11
11
12
12
12
13
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14
15
16
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17
18
19
19
20
21
21
22
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23
24
27
28
29
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TABLE OF CONTENTS
SECTION 8 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Process Control Module PC4 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Diagnostic LED’s On Process Control Module PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. User Interface Module PC7 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Diagnostic LED’s On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Automation Interface Module PC9 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Diagnostic LED’s On Automation Interface Module PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Network Status Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
32
32
33
35
36
36
37
37
38
39
41
41
42
46
Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
PipeProE 450 RFC
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1
European Contact:
Telephone:
Fax:
dec_stat_2/04
Mr. Danilo Fedolfi, Managing Director
ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98290−203
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-223 586 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-223 586 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-223 586 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-223 586 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-223 586 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-223 586 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-223 586 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-223 586 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − DEFINITIONS
3-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
1
1.1
1.2
1.3
2.1
2.2
2.3
2
2.1
2.2
2.3
3
3.1
3
3.1
3.2
3.2
3.3
3.3
4
5
4.1
+
4
+
+
+
4.1
6
5
6
S-179 310
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
1/96
OM-223 586 Page 9
1
1
2
3
4
5
6
V
V
> 5 min
V
219844−A
7
8
9
10
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Electric shock from wiring can
kill.
3 Disconnect input plug or
power before working on
machine.
4 Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
5 Always wait 5 minutes after
power is turned off before
working on unit, OR
6 Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
7 When power is applied failed
parts can explode or cause
other parts to explode.
8 Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
9 Always wear long sleeves and
button your collar when
servicing unit.
10 After taking proper
precautions as shown,
connect power to unit.
4/04
1
1
2
3
∠ = <60 °
4
∠
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both eye bolts. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one eye bolt to lift
or support unit.
S-179 309-A
2
3
4
5
1/96
OM-223 586 Page 10
3-2. Symbols And Definitions
A
Direct Current
(DC)
Alternating
Current (AC)
Output
Circuit Breaker
Remote
On
Off
Positive
Negative
Voltage Input
Arc Force
Constant Voltage
Inductance
Protective Earth
(Ground)
Line Connection
Gas Metal Arc
Welding (GMAW)
Three Phase Static
Frequency ConverterTransformerRectifier
Increase
U0
Rated No Load
Voltage (Average)
Hz
Hertz
U1
IP
Primary Voltage
Degree Of
Protection
U2
I2
Pulsed
I1max
V
Amperage
Rated Maximum
Supply Current
Conventional
Load Voltage
Rated Welding
Current
Single Phase
I1eff
Maximum Effective
Supply Current
S
X
%
Voltage
Duty Cycle
Percent
Three Phase
Suitable for Some
Hazardous
Locations
3-3. Manufacturer’s Rating Label
5/04 − 220 536-B
OM-223 586 Page 11
SECTION 4 − INSTALLATION
NOTE
Appearance of actual unit may vary from unit shown in manual.
4-1. Specifications
Rated
Welding
Output
Input
Power
Three
Phase
Voltage
Range
450 A @
44 V DC,
100%
Duty
Cycle
Max
Open
Circuit Voltage
DC
10-44
80
Amperes Input At
Rated Load Output
60 Hz,
Three-Phase
Input
kVA
Input
KW
19.46
(0.8*)
18.68
(0.17*)
400V
29.7
(0-1A*)
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
4-2. Dimensions And Weight
Hole Layout Dimensions
A
A
17-3/32 in (434 mm)
B
17-3/8 in (441 mm)
C
19-3/32 in (485 mm)
D
16-3/32 in (409 mm)
E
1/2 in (13 mm)
E
22-1/2 in
(572 mm)
31 in
(787 mm)
C
B
Weight
17-3/32 in
(434 mm)
163 lb (74 kg) Net
180 lb (82 kg) Ship
OM-223 586 Page 12
D
Ref. 803 244-B
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
100% Duty Cycle At 450 Amperes
60% Duty Cycle At 580 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 220 485-A
4-4. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
CV MODE
80
70
. This
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
60
VOLTAGE
50
40
30
20
10
0
0
100
200
300
AMPERAGE
400
500
600
700
va_curve1 4/95 − 220 486-A
OM-223 586 Page 13
4-5. Selecting A Location
Movement
Tipping
Y Do not move or operate
unit where it could tip.
2
OR
1
Location
Y Special installation may be required where gasoline or volatile
liquids are present − see NEC Article 511 or CEC Section 20.
Y Do not stack units. Beware of
tipping.
1
Lifting Forks
Use lifting forks to move unit.
4
Extend forks beyond opposite side
of unit.
3
2
18 in
(460 mm)
Hand Cart
Use cart or similar device to move
unit.
3
Rating Label
Use rating label to determine input
power needs.
4
Line Disconnect Device
Locate unit near correct input
power supply.
18 in
(460 mm)
loc_2 3/96 -Ref. 803 244-B
OM-223 586 Page 14
4-6. Equipment Connection Diagram
1
2
Welding Power Source
Negative Volt Sense Cable
Connect plug on end of volt sense
cable to volt sense receptacle on
front of welding power source.
4
3
4
Extension Cable (Optional)
Interconnect Cable
Connect 14-pin socket into wire
feeder control cable. Connect
72-pin connector to I/O receptacle
RC72 on rear of power source.
Connect 10-pin connector into
wirefeed receptacle RC8 on rear of
power source.
5
6
7
8
9
10
11
12
13
1
4
Negative (−) Weld Cable
Positive (+) Weld Cable
Workpiece
14-Pin Feeder Control Cable
Wire Feeder
Gun Trigger Receptacle
Gun
Gas Hose
Gas Cylinder
13
3
12
6
2
9
5
8
10
7
11
Ref. 803 757-A
OM-223 586 Page 15
4-7. Rear Panel Receptacles And Circuit Breakers
4
5
6
1
1
2
3
2
115 V 10 A AC Receptacle RC2
Receptacle supplies 60 Hz singlephase power. Maximum output from
RC2 is limited by circuit breaker CB2 to
10 amps.
Circuit Breaker CB1
Circuit Breaker CB2
CB1 protects 115 volt receptacle RC2
from overload. If CB1 opens, RC2 does
not work.
3
CB2 protects the wire feeder from
overload. If CB2 opens, the wire feeder
does not work.
. Press
button to reset breaker. If
breaker continue to open, contact a
Factory Authorized Service Agent.
4
Wire Feed/Gas Receptacle RC8
Use receptacle to connect Pipepro
interconnect cable to power source
(see Sections 4-6 and 8 for additional
information).
5
Peripheral Receptacle RC25
Receptacle provides connection to
water flow switch and I/O relay contacts
circuitry (see Section 4-10).
6
Interface Receptacle RC72
Use receptacle to connect PipePro
interconnect cable (see Sections 4-6
and 8 for additional information).
Ref. 803 245-B
4-8. Connecting To Weld Terminals
Y Turn off power before
connecting to weld output
terminals.
Determine total cable length in
weld circuit (both positive and
negative cables combined) and
maximum welding amperes. See
Section 4-9 to select proper
cable size.
1
2
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
Connect positive weld cable to
Positive (+) weld terminal and
negative (−) cable to Negative
weld terminal.
1
Tools Needed:
2
3/4 in
OM-223 586 Page 16
Ref. 803 244-B
4-9. Selecting Weld Cable Sizes*
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Weld Cable Size*** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding****
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105
m)
400 ft
(120
m)
Weld Output
Terminals
Y Turn off power before
connecting to weld output terminals.
Welding
Amperes**
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0
(120)
4/0
(120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0
(120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0
(120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0
(120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0
(120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
700
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
800
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)
900
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
1000
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
1250
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
4 ea. 3/0
(4x95)
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
Positive
)
Negative
*
Ref. 803 246-B
10 − 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Cable should be sized for Peak Amperage (Apk) for pulse welding applications.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-223 586 Page 17
4-10. Peripheral Receptacle Functions
C B
D
L
E
F
H
M
J
Function
A
K
Socket
A
Not used.
B
Not used.
C*
Circuit common.
D
Not used.
E
Contact closure to F indicates coolant flow switch is
closed and recirculating coolant system is
operational.
F*
Circuit common.
H
Not used.
J
Not used.
K
Not used.
L
Not used.
M
Not used.
Coolant Flow
Switch Input
Signal
Ref. 803 245-B
Socket Information
*Circuit common is same electrical reference point.
Note: A customer supplied matching amphenol plug, factory Part No. 194 847, [Amphenol Part No. 97-3106A-20-33P(B)(621) and strain relief
clamp 97-3057-12(0621)] is required to use peripheral receptacle.
OM-223 586 Page 18
4-11. Motor Control Receptacle Functions
G
J
K
Socket
C
A
F
E
H
D
C
B
Socket Information
A
Not used.
B
+40 volts dc.
C
Not used.
D
+40 volts dc return.
E
Not used.
F
Not used.
G
Electrode sense.
H
Not used.
J
Not used.
K
Not used.
Ref. 803 245-B
4-12. Electrical Service Guide
50/60 Hz
Input Voltage
400
Input Amperes At Rated Output
28
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2
35
Normal Operating 3
40
Min Input Conductor Size In AWG
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
10
211
(64)
10
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
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).
OM-223 586 Page 19
4-13. Connecting Input Power
Y Turn Off welding power source,
and check voltage on input
capacitors
according
to
Section 8-3 before proceeding.
Y Incorrect connections
cause electric shock
damage to the machine.
Y Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
1
Y Disconnect input power before
opening door for voltage
connections.
3
1
Clamp
Install clamp of proper size for unit and
input conductors.
L1
L2
will
and
2
2
Input And Grounding Conductors
Select size and length using Section
4-12.
L3
Connect input conductors as shown in
illustration.
= GND/PE
Connect grounding conductor first,
then line input conductors. Always
connect green wire to supply
grounding terminal, never to a line
terminal.
Y Always connect grounding
conductor first.
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
Tools Needed:
Double-check grounding conductor,
inside voltage connections, and input
voltage before applying power.
5/16 in
3
Line Disconnect Device
See Section 4-12.
Close door before operating unit.
Route input conductors
to filter board.
Route ground conductor through
tubing and current transducer to
ground terminal.
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219842−A
803 245-C / 219 842-A
OM-223 586 Page 20
4-14. Remote Program Select
NOTE
Remote Program Select is factory set to “On”. WaveWriter or File Management
software is required to turn this function “Off”.
When Remote Program Select is On, a remote device or pendant may be used to select programs. When Off, program
selection must be done from the welding power source front panel.
4-15. Remote Program Setting
NOTE
When Remote Program Select is “On”, program selection will be determined by
remote input once a weld is initiated. Prior to welding, program selection can be
done in a normal manner from the welding power source front control panel.
See the following table for the remote program select binary code.
Program No.
Output A
Output B
Output C
1
Off
Off
Off
2
On
Off
Off
3
Off
On
Off
4
On
On
Off
5
Off
Off
On
6
On
Off
On
7
Off
On
On
8
On
On
On
OM-223 586 Page 21
SECTION 5 − OPERATION
5-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Accu-pulse
Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds.
Adaptive response is controlled by peak and minimum current levels. Benefits are shorter arc lengths, better
puddle control, more tolerant of tip-to-work variation, less audible noise, no arc wandering, allows weld to fill in
at toes increasing travel speed and deposition, and more tolerant to poor fit up and gaps.
Adjust
Control knob used to change or set parameters and functions.
Amps
Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Adjust
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual
arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by volts in MIG
programs.
Arc Control
Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD
(optional).
Arc Length
Distance from end of wire electrode to workpiece.
Gas Type
Selection of shielding gas being used in application.
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per
second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes
the welding puddle more fluid.
MIG
CV weld process with individual settings of voltage and wire speed.
Process
A selection made for MIG, Pulse, Accu-pulse, and RMD.
Process Set Up
Selection procedure for entering program.
Program
Eight active slots for selection of various processes, wire types, and parameters.
Program Load
Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).
Pulse
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory
taught data. Adaptive method is controlled by frequency adjustment.
RMD
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of RMD are well
suited to thin materials, improves gap filling and spatter reduction. Provides less heat input into workpiece,
minimizes distortion and allows use of larger diameter wire on thin gauge materials.
Sharp Arc
In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory
pulse data. In RMD this control will affect the arc in much the same way as inductance.
Synergic
Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual pulse
settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed
speed setting.
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.
Wire Type
Selection of wire type by alloys and classification.
OM-223 586 Page 22
5-2. Front Panel Controls (See Section 5-3)
15
14
13
1
4
12
V
A
A
3
11
10
8
5
9
6
7
Adjust
Setup
Arc Control
2
. When an LED is lit, it means the related function is active.
219 712-A
1 Program Display
Displays the number of the active program.
2 Adjust Knob
Turn the Adjust knob to change program
number, Setup, Arc Control, and weld
parameters.
3 Program Push Button LED
The LED lights when the Program Push
Button is active.
4 Program Push Button
Press push button (LED lights) and turn Adjust
knob to select active program.
The letter C is displayed with the program
number if the program has been changed from
the factory settings using the optional PDA
with File Management/WaveWriter software
(see File Management/WaveWriter Owner’s
Manual).
. The program cannot be changed through
the front panel while welding.
Press and hold button to see program name.
Custom programs are named using optional
PDA with File Management/WaveWriter
software. Program name is shown in upper
and lower displays (items 13 and 15).
5
Setup Mode Indicators
Gas Type LED
When this LED is lit, turn the Adjust knob to
select the desired weld gas. Gas type choices
vary according to the selected weld process.
The lit LED indicates which setup mode is
active. Setup mode parameters are shown in
Display Windows (see Items 13 and 15).
See Table 5-1 for all gas abbreviations.
Process LED
The LED lights to indicate one of the setup
modes is active.
When this LED is lit, turn the Adjust knob to
select the desired weld process. Choices
include pulse welding (displayed as PULS),
Accu-pulse, MIG welding (MIG), and Accu
Puls/RMD [Regulated Metal Deposition
(optional)].
Wire Type LED
When this LED is lit, turn the Adjust knob to
select the desired wire type, wire alloy, and
size. Wire type and size choices vary
according to the selected weld process.
Choices may include steel (displayed as
STL), stainless steel (SS), metal core
(MCOR), aluminum (ALUM). See Table 5-1
for all wire abbreviations.
6
7
Setup Push Button LED
Setup Push Button
Press button to select Process, Wire Type,
Wire Diameter, or Gas Type parameters.
. In order for selections to be retained in
memory, the Setup push button must be
pressed six times before any other push
button is pressed: once to select Process,
again to select Wire Type, again to select
Wire Alloy, again to select Wire Size,
again to select Gas Type, and a sixth time
to store selections in memory. The
displays will temporarily show “PROG
LOAD” to indicate the data is being stored
in memory.
OM-223 586 Page 23
5-3. Front Panel Controls - Continued (See Section 5-2)
8
Arc Control LED
The LED lights to indicate the Arc Control
button is active. Light goes out when button is
inactive.
9
Arc Control Push Button
This push button allows fine tuning inductance
for MIG programs, and Arc Control for
programs other than MIG. When the push
button is pressed, the upper display (item 15)
shows INDU for inductance, or ARC for Arc
Control to indicate which parameter is
selected for change. The range of possible
values is 0-99 for inductance, and 0-50 for arc
control. Turn the Adjust knob to change the
parameter value. Press button to deactivate
arc control mode (LED goes out).
10 Wire Feed/Gas/Contactor LEDs
The Contactor LED lights when the output
contactor is energized, making the weld
output terminals live.
11 Wire Speed And Amps LED’s
The lit LED indicates whether wire speed or
amps are being displayed.
12 Wire Feed Speed/Amps Display Push
OM-223 586 Page 24
Button
13 Lower Display
Press Wire Feed Speed/Amps Display button
to show weld amperage or wire feed speed in
lower display (the applicable LED under the
lower display lights to indicate which is
shown). When welding, actual value is shown.
If amperage was selected for display, the unit
will show actual welding amperage prior to
and while welding unless the the unit is in
Display Command Values mode. Only wire
speed command will be displayed while
welding if the unit is set in Display Command
Values mode, even if the Wire Feed
Speed/Amps Display button is pressed.
. Displays show actual or command values
as determined by configuration menu
when using a PDA with File Management/
WaveWriter software. Command values
are displayed prior to welding and actual
values are displayed while welding unless
a PDA with File Management software
was used to set the unit in the ”Display
Command Values” mode. In the Display
Command Values mode, command
values are displayed while welding.
. If a PDA with File Management/WaveWriter
software is used to change wire feed units
(IPM, MPM) or display welding information
(command or actual),save the changes and
then turn the power to the unit off and then
on again for the changes to be carried out
by the unit.
14 Volts And Arc Adjust LED’s
The lit LED indicates whether voltage or arc
length is being displayed.
15 Upper Display
The upper display shows different information
depending on the active function of the unit
and the weld process being used. When the
display shows voltage (for a MIG process),
the Volts LED lights. When it shows arc adjust
[for a pulsed and RMD (optional) weld
process], the Arc Adjust LED lights. However,
during any weld process (MIG and pulse), the
unit will display actual arc voltage unless a
PDA with File Management/WaveWriter
software has set the unit in the ”Display
Command Values” mode.
Table 5-1. Welding Programs
Process
Wire Type
Alloy
Type
Diameter
inch
.035
035
E70
Steel
.040
mm
09
0.9
1.0
STL
.045
1.2
RMD
Stainless
St
i l
Steel
Metal
Core
SS
MC
STL
meter/min
50−400
1.3−10.2
50−350
1.3−8.9
50−350
1.3−6.4
50−250
1.3−6.4
100% CO2
CO2
75% Argon, 25% CO2
C25
90% Argon, 10% CO2
C10
95% Argon, 5% Oxygen
OX5
85% Argon, 15% CO2
C15
100% CO2
CO2
75% Argon, 25% CO2
C25
85% Argon, 15% CO2
C15
90% Argon, 10% CO2
C10
95% Argon, 5% Oxygen
OX5
100% CO2
CO2
50−400
1.3−10.2
.035
035
09
0.9
85% Argon, 15% CO2
C15
50−350
1.3−8.9
E100
.040
1.0
85% Argon, 15% CO2
C15
50−350
1.3−8.9
.035
0.9
90% HE, 7.5% Ar, 2.5% CO2
TRIH
50−250
1.3−6.4
90% HE, 7.5% Ar, 2.5% CO2
TRIH
98% Argon, 2% Oxygen
OX2
50−250
1 3−6 4
1.3−6.4
90% HE, 7.5% Ar, 2.5% CO2
TRIH
98% Argon, 2% Oxygen
OX2
50−250
1 3−6 4
1.3−6.4
85% Argon, 15% CO2
C15
50−250
1.3−6.4
95% Argon, 5% CO2
C5
50−780
1.3−19.8
50−780
1.3−19.8
50−780
1.3−19.8
50−780
1.3−19.8
308,
308
316
MC71,
MC76,
MC90
.040
040
10
1.0
.045
045
12
1.2
.045
1.2
.045
Steel
inch/min
E80
.035
Pulse
WFS Range
Gas Mixture
0.9
1.2
E70
.052
.062
1.3
1.6
90% Argon, 10% CO2
C10
95% Argon, 5% Oxygen
OX5
95% Argon, 5% CO2
C5
90% Argon, 10% CO2
C10
95% Argon, 5% Oxygen
OX5
95% Argon, 5% CO2
C5
90% Argon, 10% CO2
C10
95% Argon, 5% Oxygen
OX5
95% Argon, 5% CO2
C5
90% Argon, 10% CO2
C10
95% Argon, 5% Oxygen
OX5
OM-223 586 Page 25
Table 5-1. Welding Programs (Continued)
Process
Wire Type
Alloy
Type
Diameter
inch
mm
.035
0.9
.040
1.0
.045
1.2
E70
Steel
STL
.052
AccuA
Pulse
E100
E120
SS
OM-223 586 Page 26
MC
C5
90% Argon, 10% CO2
C10
95% Argon, 5% Oxygen
OX5
85% Argon, 15% CO2
C15
90% Argon, 10% CO2
C10
80% Argon, 20% CO2
C20
98% Argon, 2% Oxygen
OX2
90% Argon, 10% CO2
C10
80% Argon, 20% CO2
C20
98% Argon, 2% Oxygen
OX2
90% Argon, 10% CO2
C10
80% Argon, 20% CO2
C20
inch/min
meter/min
50−780
1.3−19.8
50−780
1.3−19.8
50−780
1.3−19.8
50−780
1.3−19.8
50−780
1.3−19.8
1.6
98% Argon, 2% Oxygen
OX2
.040
1.0
85% Argon, 15% CO2
C15
50−780
1.3−19.8
.045
1.2
85% Argon, 15% CO2
C15
50−780
1.3−19.8
.045
1.2
90% Argon, 10% CO2
C10
50−780
1.3−19.8
90% HE, 7.5% Ar, 2.5% CO2
TRIH
81% Ar, 18% HE, 1% CO2
TRIA
50−780
1.3−19.8
98% Argon, 2% Oxygen
OX2
90% HE, 7.5% Ar, 2.5% CO2
TRIH
81% Ar, 18% HE, 1% CO2
TRIA
50−780
1.3−19.8
98% Argon, 2% Oxygen
OX2
0.9
308,
316
.045
Metal
M
t l
Core
90% Argon, 5% CO2
.062
.035
Stainless
Steel
1.3
WFS Range
Gas Mixture
1.2
MC71,
MC76
.045
1.2
90% Argon, 10% CO2
C10
50−780
1.3−19.8
.052
1.3
90% Argon, 10% CO2
C10
50−780
1.3−19.8
MC90
.045
1.2
85% Argon, 15% CO2
C15
50−780
1.3−19.8
5-4. Front Panel Switches
4
1
3
5
6
2
1 Power Switch
Turns unit On or Off.
The power-up sequence may last up to 30
seconds before the unit is ready to weld.
During power-up, the front panel will display
messages indicating the status of the unit. The
first message is:
NET
WAIT
NET WAIT is an abbreviation for ”network
updating” and means the internal control
network is powering up. The next message is
Ref. 803 246-B
XXXX (Adapter Type)
loaded.
XXXX identifies the adapter being used as
identified by the unit. To ensure proper operation of the system, verify the adapter displayed
corresponds to the actual adapter being used.
The final message is
2
3
Gas LED
AUTO
450
4
Wirefeed LED
5
PDA Port
AUTO 450 indicates the software being
6
PC Port
Contactor LED
Contactor LED illuminates when weld output is
energized.
OM-223 586 Page 27
5-5. Reset Mode
. Reset mode is not active when
RST
NO
Program Lock is enabled.
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
. System configuration data will be
lost during the Reset operation.
Enter reset mode by turning power On and pressing
the Program Push Button until the RST NO message
is displayed. RST NO message will not display until
after the power-up sequence is completed
(approximately 20 seconds).
RST
YES
Rotate Adjust knob to change NO
to YES.
RST
YES
CYCL
PWR
Press the Arc Control button to
confirm the reset.
Cycl Pwr message appears on the display
when programs complete loading.
The reset message is displayed for
2 seconds while factory program
settings are being reloaded.
Turn power off, wait 10 seconds, and turn
power back on again to complete the reset
operation.
During the reset mode the following
factory default programs are loaded
into the unit:
Program 1
Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2
MIG
.035 Mild Steel
75% Argon, 25% CO2
Program 3
Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
Program 4
Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5
MIG
.045 Mild Steel
75% Argon, 25% CO2
Program 6
Accu-pulse
.045 Mild Steel
90% Argon, 10% O2
Program 7
Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8
MIG
.052 Mild Steel
75% Argon, 25% CO2
. After
Reset is complete, be sure to load
appropriate programs that contain the
correct wire size, process, and shielding gas
for the welding operation
198 993 / Ref. 803 246-B
OM-223 586 Page 28
SECTION 6 − MAINTENANCE
6-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Clean And
Tighten
Weld
Terminals
Replace
Damaged Or
Unreadable
Labels
Replace Damaged
Gas Hose
Repair Or Replace
Cracked Cables
And Cords
6 Months
Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
6-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 803 244-B
OM-210 540 Page 29
SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING
7-1. Symbol Usage
safety_stm 8/03
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.
7-2. Servicing 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.
Y Only qualified persons should service, test, maintain, and repair this unit.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
D
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
D
Do not leave live unit unattended.
D
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
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.
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.
FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
OM-223 586 Page 30
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on welding
gun or torch.
EXPLODING PARTS can cause injury.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing meter lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
FALLING UNIT can cause injury.
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.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
OVERUSE can cause OVERHEATING.
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.
H.F. RADIATION can cause interference.
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 install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts.
7-3. 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.
7-4. 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:
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.
OM-223 586 Page 31
SECTION 8 − TROUBLESHOOTING
8-1. Set Value Mode
V
A
A
1
Setup
Adjust
4
Arc Control
2
3
The Set Value mode is a troubleshooting tool
that allows certain robot command values to
be manually over-ridden.
1
Setup Push Button
2
Arc Control Push Button
3
Adjust Knob
4
Wire Feed Speed/Amps Display Push
Button
OM-223 586 Page 32
Enter the Set Value mode by pressing the
Setup and Arc Control push buttons at the
same time. When in the Set Value mode the
display windows briefly shows SET VALU and
the blinking LED’s under the display windows
indicate whether Volts, Arc Adjust, or Wire
Speed can be changed turning the Adjust
knob.
Depending on the defined weld process,
either volts (MIG) or arc adjust [pulse,
Accu-pulse, or RMD (optional)] can be
changed in the top display. Wire speed can be
changed in the bottom display. Press the Wire
Feed Speed/Amps push button to toggle
between selecting information in the top
display or bottom display. The LED under the
active display will blink to indicate the value
that can be changed.
Rotate the Adjust knob to change values.
Exit the Set Value mode by pressing the Setup
and Arc Control push buttons at the same time
or turning power source off and then back on
again.
8-2. Diagnostics
The following error messages are shown on the
upper and lower displays to indicate specific errors.
Explanations are in the text below:
ERR
ERR
ERR
ERR
ERR
ERR
ARC
COOL
FLOW
GND
LINE
MOTR
Indicates an arc
error.
Indicates a coolant
flow error.
Indicates a gas
flow error.
Indicates a ground
current error.
Indicates a line
error.
Indicates a motor
error.
ERR
ERR
ERR
ERR
ERR
LOW
STRT
STUK
TACH
TEMP
WFS
WFS
Indicates an arc
start error.
Indicates a wire
stuck error.
Indicates a
tachometer error.
Indicates a
temperature error.
Indicates a wire
feed speed error.
Indicates a low WFS
command error.
ERR ARC
ERR LINE
ERR TACH
• The arc error indicates an arc outage
occurred possibly from a wire feeder error
or power source error. Check wire feeder
and power source. Press Jog/Purge button
to clear error.
• The line error indicates input power is
outside of unit operating range. Check and
correct input power. Press Jog/Purge
button to clear error.
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The motor
speed is regulated through the monitoring of
voltage and current. Press Jog/Purge
button to clear error.
ERR COOL
• The motor error indicates that the motor
has been drawing too much current for too
long. To remedy this, reduce the wire feed
speed or the wire feeder torque load/duty
cycle. Press Jog/Purge button to clear error.
• The cool error indicates no coolant flow in
water flow switch option. The error may be
reset by reestablishing coolant flow to the
gun, and then pressing the Jog/Purge
button.
ERR FLOW
• The flow error indicates no gas flow to the
gun. The error may be reset by
reestablishing gas flow to the gun, and then
pressing the Jog/Purge button.
ERR MOTR
ERR STRT
• The start error occurs if the user has the
trigger held for more than 3 seconds without
striking an arc and Start Err is enabled. This
error also occurs if trigger jog runs for 30
seconds or more. The error may be cleared
by releasing the trigger, and pressing the
Jog/Purge button.
ERR TEMP
• The temperature error indicates welding
power source has overheated and
shutdown. The error may be cleared by
allowing unit to cool down, and pressing the
Jog/Purge button.
ERR WFS
• The wire feed speed error indicates actual
wire feed speed does not match wire feed
speed command. Press Jog/Purge button
to clear error.
ERR GND
ERR STUK
LOW WFS
• The ground current error occurs if weld
current is detected in the earth ground
connection. May be caused by a conductor
making contact with unit chassis. Check
and repair feeder weld connections. Press
Jog/Purge button to clear error.
• The stuck error occurs if the welding wire
sticks to the workpiece at the end of a weld.
May be caused by poor weld conditions.
The error may be cleared by cutting wire
from workpiece, and pressing the Jog/
Purge button.
• The low wire feed speed error indicates
actual wire feed speed is lower than wire
feed speed command. Check for
obstructions in the wire feed system or a
faulty wire drive system. Press Jog/Purge
button to clear error.
OM-223 586 Page 33
8-2.
Diagnostics (Continued)
MOTR
OVER
PLS
OVER
COM
CRNT
WAIT
MAX
Indicates a motor
communication error.
Indicates an
overcurrent error.
MOTR COM
• The motor common error indicates wire
feed module lost data communications.
Press Jog/Purge button to clear error.
OVER CRNT
• The over current error indicates welding
power source primary current is too high.
Check and correct input power. Press Jog/
Purge button to clear error.
OM-223 586 Page 34
Indicates a UIM
communication error.
Indicates an over
maximum average
current error.
PLS WAIT
• The uim communication error indicates
user interface module lost data
communications. Press Jog/Purge button
to clear error.
OVER MAX
• The over max error indicates that the
average current has exceeded 600
amperes.
8-3. Removing Cover and Measuring Input Capacitor Voltage
Y 900 Volts dc can be present on the capacitor bus and
significant DC voltage can remain on capacitors
after unit is Off. Always check the voltage on both
inverter assemblies as shown to be sure the input
capacitors have discharged before working on unit.
Tools Needed:
5/16 in
Turn Off welding power source, and
disconnect input power.
Remove cover
1
Power Interconnect Board
PC2
2
Voltmeter
Measure the dc voltage across the
+ bus terminal and − bus terminal on
PC2 as shown until voltage drops to
near 0 (zero) volts. Measure input
capacitor voltage on both inverter
assemblies before proceeding.
Proceed with job inside unit.
Reinstall cover when finished.
1
2
+ lead to left bus terminal, − lead to right bus terminal
1
2
+ lead to left bus terminal, − lead to right bus terminal
802 985 / Ref. 803 250-C
OM-223 586 Page 35
8-4. Process Control Module PC4 Diagnostic LED’s
1
Process Control Module PC4
Diagnostic LED’s are visible inside unit,
located on PC4 mounted on the top tray.
Refer to Section 8-5 for information on
diagnostic LED’s.
1
Reinstall cover after checking diagnostic
LED’s.
LED1
LED2
LED3
LED4
216 956-A / Ref. 803 250-C
8-5. Diagnostic LED’s On Process Control Module PC4
LED
Status
1
On
Indicates −25 volts dc is present on process control module PC4
Off
Indicates −25 volts dc is not present on process control module PC4
On
Indicates +25 volts dc is present on process control module PC4
Off
Indicates +25 volts dc is not present on process control module PC4
On
See Network Status Table in Section 8-10
Off
See Network Status Table in Section 8-10
2
3,4
OM-223 586 Page 36
Diagnosis
8-6. User Interface Module PC7 Diagnostic LED’s
LED1
2
LED2
3
1
218 559-A / 803 251-B
1 User Interface Module PC7
Diagnostic LED’s are visible inside unit,
located on PC7 mounted behind the front
panel.
Refer to Section 8-7 for information on
diagnostic LED’s.
Reinstall cover after checking diagnostic
LED’s.
2
Dip Switch S1
3
Dip Switch S2
Dip switches are used to identify each
circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.
8-7. Diagnostic LED’s On User Interface Module PC7
LED
Status
Diagnosis
1, 2
On
See Network Status Table in Section 8-10
Off
See Network Status Table in Section 8-10
OM-223 586 Page 37
8-8. Automation Interface Module PC9 Diagnostic LED’s
1
LED11
LED13 LED25
LED28
LED12
LED14
LED27
LED31
LED30
LED1
LED2
LED3
LED4
2
LED5
LED6
LED7
LED8
LED9
LED10
LED32
LED33
LED15
LED20 LED19 LED18 LED16
LED17
LED21 LED22 LED23 LED24 LED26 LED29
216 958-A / Ref. 803 250-C
1 Automation Interface Module PC9
Diagnostic LED’s are visible inside unit,
located on PC9 mounted on left side.
Refer to Section 8-9 for information on
diagnostic LED’s.
OM-223 586 Page 38
Reinstall cover after checking diagnostic
LED’s.
2
Dip Switch S4
Dip switches are used to identify each
circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.
8-9. Diagnostic LED’s On Automation Interface Module PC9
LED
Status
1
On
Input signal On from robot for jog advance
Off
Input signal Off from robot for no jog advance
On
Input signal On from robot to energize contactor
Off
Input signal Off from robot to not energize contactor
On
Input signal On remote program A selected
Off
Input signal Off remote program A not selected
On
Input signal On remote program C selected
Off
Input signal Off remote program C not selected
On
Input signal On from E-stop board PC12 for no emergency stop
Off
Input signal Off from E-stop board PC12 acknowledges E-stop is On from robot
On
Spare 1 not assigned
Off
Spare 1 not assigned
7
On
Input signal On Autoset-C selected
Off
Input signal Off Autoset-C not selected
8
On
Input signal On Autoset-B selected
Off
Input signal Off Autoset-B not selected
On
Input signal On Remote Jog on from peripheral plug
Off
Input signal Off Remote Jog off from peripheral plug
10
On
Input signal On Remote Purge on from peripheral plug
Off
Input signal Off Remote Purge off from peripheral plug
11
On
Input signal On from robot for jog retract
Off
Input signal Off from robot for no jog retract
On
Input signal On from robot for purge
Off
Input signal Off from robot for no purge
13
On
Input signal On remote program B selected
Off
Input signal Off remote program B not selected
14
On
Input signal On Touch Sensor on from robot or peripheral plug
Off
Input signal Off Touch Sensor off from robot or peripheral plug
On
Spare 0 not assigned
Off
Spare 0 not assigned
16
On
Spare 2 not assigned
Off
Spare 2 not assigned
17
On
Input signal On Autoset-A selected
Off
Input signal Off Autoset-A not selected
On
Input signal On Autoset-D selected
Off
Input signal Off Autoset-D not selected
On
Input signal On Remote Retract on from peripheral plug
Off
Input signal Off Remote Retract off from peripheral plug
On
Input signal On Remote Water Flow on from peripheral plug
Off
Input signal Off Remote Water Flow off from peripheral plug
On
Input signal On from robot for no emergency stop
Off
Input signal Off from robot for emergency stop
On
Input signal On from relay K3 for welding power source ready and no detected errors present
Off
Input signal Off from relay K3 for welding power source not ready, detected errors are present, or unit is
in operating mode preventing the weld ready signal from being enabled
2
3
4
5
6
9
12
15
18
19
20
21
23
Diagnosis
OM-223 586 Page 39
LED
Status
24
On
Input signal On from relay K4 to indicated wire stuck in weld joint
Off
Input signal Off from relay K4 to indicate wire is not stuck in weld joint
25
On
Indicates +5 volts dc is present on automation module PC9
Off
Indicates +5 volts dc is not present on automation module PC9
26
On
Input signal on from relay K5 for flow (shielding gas or coolant) present
Off
Input signal off from relay K5 for flow (shielding gas or coolant) not present
On
Indicates −15 volts dc is present on automation interface module PC9
Off
Indicates −15 volts dc is not present on automation interface module PC9
28
On
Indicates +15 volts dc is present on automation interface module PC9
Off
Indicates +15 volts dc is not present on automation interface module PC9
29
On
Input signal on from relay K6 for arc detected
Off
Input signal off from relay K6 for no arc detected
On
See Network Status Table in Section 8-10
Off
See Network Status Table in Section 8-10
32
On
Input signal on for aux. relay energized
Off
Input signal off for aux. relay energized
33
On
Input signal on touch sensor touch detected
Off
Input signal off touch sensor touch not detected
27
30, 31
OM-223 586 Page 40
Diagnosis
8-10. Network Status Table
Circuit boards PC4, PC7, and PC9 have two bi-color (green/red) LED’s to give information about communication between circuit boards. See the table below for an explanation of what the LED’s indicate.
Status
Diagnosis
Off
There is no power applied to the circuit board or the board software is not executing.
Green
The circuit board is operating normally.
Flashing Green
Flashing Red
The circuit board is in a communication standby mode. Wait or cycle power to clear standby mode.
The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.
Circuit board is unable to communicate with circuit board PC4.
Red
The circuit board has encountered an unrecoverable fault. Verify dip switch positions according to Sections 8-6 and 8-8. Replace circuit board if necessary.
Flashing RedGreen
The circuit board is performing a communication self-test.
8-11. Troubleshooting
Trouble
No weld output; completely inoperative
Remedy
Place line disconnect in On position (see Section 4-13).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-13).
Check for proper input power connections (see Section 4-13).
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.
error displayed.
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 4-9).
errors displayed.
displayed
Check that proper program for wire size, process, and shielding gas is loaded.
Clean and tighten all weld connections.
No 115 volts AC at the duplex receptacle. Reset circuit breaker CB1.
Wirefeeder has no power.
Check circuit breaker CB2 and reset if necessary.
Check motor control cable connections.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
source
Check voltage sense lead connection, clean and tighten if necessary.
OM-223 586 Page 41
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)
OM-223 586 Page 42
223 581-A (Part 1 Of 2)
OM-223 586 Page 43
Figure 9-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)
OM-223 586 Page 44
223 581-A (Part 2 Of 2)
OM-223 586 Page 45
SECTION 10 − PARTS LIST
. Hardware is
common and
not available unless listed.
2
1
3
4 − Fig 10-3
5 − Fig 10-2
7 − Fig 10-4
6
9
5
16 − Fig 10-5
10
15
11
12
14
13
9
8
15
Ref. 803 247-C
Figure 10-1. Main Assembly
OM-223 586 Page 46
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
. . . . . T2 . . . . . . . 212543
. . . . . . . . . . . . . . . . 210492
. . . . . . . . . . . . . . . . 210481
. . . . . . . . . . . . . . . Fig 10-3
. . IM1, IM2 . . . . 222959
. . . . . . . . . . . . . . . . 198961
. . . . . . . . . . . . . . . Fig 10-4
. . . . . . . . . . . . . . . . 207898
. . . . . . . . . . . . . . . . 210482
. . . . . W1 . . . . . . . 180270
. . . . . . . . . . . . . . . . 213386
. . . . HD2 . . . . . . 182918
. . . . . . . . . . . . . . . . 198951
. . . . . . . . . . . . . . . . 148025
. . . . . . . . . . . . . . . . 213372
. . . . . . . . . . . . . . . Fig 10-5
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . MODULE, inverter assy (300A) (Fig 10-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Module Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side (LH & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Contactor, DEF PRP 40A 3P 24VAC Coil W/Boxlug . . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
+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.
14
. Hardware is
15
common and
not available unless listed.
16
2
1
3
4
5
13
6
12
7
11
8
9
34
10
6
35
36
7
18
17
19
20
33
32
21 22
31
30
24
25
26
24
28
13
37
29
27
23
24
39
38
802 955-A
Figure 10-2. Windtunnel Assembly LH And RH
OM-223 586 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Windtunnel Assembly LH And RH (Fig 10-1 Item 6)
... 1 ................
... 2 ................
. . . 3 . . . . . L1 . . . . . . .
... 4 ................
. . . 5 . . . R3, C4 . . . . .
... 6 ................
. . . 7 . . . D1, D2 . . . . .
... 8 ................
... 9 ................
. . . 10 . . . . . T1 . . . . . . .
. . . 11 . . . . . Z1 . . . . . . .
. . . 12 . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . .
......................
. . . 17 . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . .
......................
......................
. . . . . . . . . . CT1 . . . . . .
. . . 21 . . . . . . . . . . . . . . . .
. . . 22 . . . C1, C2 . . . . .
. . . 23 . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . . .
. . . 25 RT1,RT2.RT3 . .
. . . 26 . . . . PC2 . . . . . .
. . . 27 . . . . . C3 . . . . . . .
. . . 28 . . . . . . . . . . . . . . . .
. . . 29 . . . . HD1 . . . . . .
......................
. . . 30 . . . R1, R2 . . . . .
......................
. . . 31 . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . . .
. . . 35 . . . . . L2 . . . . . . .
. . . 36 . . . . . . . . . . . . . . . .
......................
......................
. . . 37 . . . . PC1 . . . . . .
. . . 38 . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . . . .
214597
196351
213940
214519
196518
199840
201531
196347
196349
203408
220496
170647
179276
196355
010546
047838
146112
222958
196332
153403
196259
115092
115091
196231
201695
203912
210507
217625
214015
222955
196143
196378
182918
196384
196343
196840
109056
196514
196512
196330
196345
196588
196365
199136
218790
196340
083147
. . . Windtunnel, LH w/Components (including). . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Heat Sink Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Xfmr, HF Litz/Litz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Output Inductor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . .
. . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . .
. . . . Blank, Snap−in Nyl 1.000 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . .
. . . . Blank, Snap-in Nyl .218 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . .
. . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Elctlt 2400 Uf 500 VDC Can 2.5 Dia . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead . . . . . . . . . . . .
. . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Current Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Transducer, Current 400A Module Supply V +/− 15v . . . . . . . . . . . . . .
. . . . Cable, Transducer 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistors, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Resistors/Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . .
. . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Coil, Inductor (Pre−regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (PC2 To PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Control (Inverter 300A) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . .
1
1
1
1
1
2
2
1
3
1
1
2
4
6
1
1
2
1
1
2
1
1
1
1
2
2
2
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
4
4
+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-223 586 Page 48
. Hardware is
1
common and
not available unless listed.
2
3
4
5
6
10
7
9
8
Ref. 802 916-B
Figure 10-3. Top Tray Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-3. Top Tray Assembly (Fig 10-1 Item 4)
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
. . . . PC12 . . . . . .
. . . . PC3 . . . . . .
................
................
................
. . . . PC4 . . . . . .
................
................
................
................
209676
221606
210490
134201
083147
221277
170647
210491
204838
198122
. . . Circuit Card Assy, E−stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off, PC Card .312/.375/Post&Lock .43 . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . .
. . . Process Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Tray, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Circuit Card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . .
1
1
1
4
24
1
1
1
1
1
+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-223 586 Page 49
. Hardware is
common and
not available unless listed.
8
5
6
9
7
4
2
3
1
10
15
11
12
14
13
803 248-D
Figure 10-4. Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-4. Rear Panel Assembly (Fig 10-1 Item 8)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
. . . . PC9 . . . . . .
................
. . . . PC10 . . . . . .
................
................
................
................
................
................
................
. . . . CB1 . . . . . .
. . . . CB2 . . . . . .
. . . . PC11 . . . . . .
. . . . RC2 . . . . . .
................
221279
199297
214855
199295
175282
207894
210358
198996
201058
210483
083432
093995
200570
604176
216596
. . . Automation Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 6-32 & no 8-32 x 2.50 lg .312 hex alm/m . . . . . . . . . . . . .
. . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 8-32 x .500 lg .312 hex al m&f . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Connector, Rect 72 Pin Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Breaker, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . . .
. . . Circuit Breaker, Man Reset 1P 15A 250VAC Frict . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Motor Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
4
1
1
1
1
1
1
1
1
1
1
1
+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-223 586 Page 50
2
1
. Hardware is
common and
not available unless listed.
4
7
6
5
26
11
10
3
24
25
23
9
10
8
22
17
16
15
11
10
12
13
18
14
12
19
21
20
Ref. 803 249-C
Figure 10-5. Front Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-5. Front Panel Assembly (Fig 10-1 Item 14)
. . . 1 . . . . . S1 . . . . . . . 207456
. . . 2 . . . . . . . . . . . . . . . . 207895
. . . 3 . . . . . . . . . . . . . . . . 179851
. . . 4 . . . . . . . . . . . . . . . . 204393
. . . . . . . . . . . . . . . . . . . . . . 204394
. . . 5 . . . . . . . . . . . . . . . . 219 712
. . . 6 . . . . . . . . . . . . . . . . 213887
. . . 7 . . . . PC7 . . . . . . 221278
. . . . . . . . . . . . . . . . . . . . . . 200416
. . . . . . . . . . . . . . . . . . . . . . 199376
. . . 8 . . . . . FM . . . . . . . 196313
. . . 9 . . . . PC13 . . . . . . 208071
. . . 10 . C6, C7, C8 . . . 206878
. . . 11 . . . . . . . . . . . . . . . . 213102
. . . 12 . . . . . . . . . . . . . . . . 025248
. . . 13 . . . . . . . . . . . . . . . . 207897
. . . 14 . . . . . . . . . . . . . . . . 210866
. . . 15 . . . . RC5 . . . . . . 214664
. . . Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . .
. . . Panel, PC Card Front (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, PC Card Switch/Overlay (including) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Nameplate, Overlay/CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . User Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Circuit Card Assy, User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Circuit Card Assy,ISO/COMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Choke, Common Mode w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . .
. . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, Common Mode Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
2
1
3
2
2
2
1
1
OM-223 586 Page 51
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-5. Front Panel Assembly (Fig 10-1 Item 14) (Continued)
...
...
...
...
...
...
...
...
...
...
...
16
17
18
19
20
21
22
23
24
25
26
................
................
................
................
................
................
................
................
................
................
................
216966
216965
215467
207896
180732
179848
221527
210865
210473
210483
210358
. . . Cover, Connector D-sub 9 pin Male w/Chain . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Connector D-sub 9 skt Female w/Chain . . . . . . . . . . . . . . . . . . . .
. . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Negative Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Positive Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
+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-223 586 Page 52
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue® for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 1/05
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
www.MillerWelds.com
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2005 Miller Electric Mfg. Co.
1/05
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