Miller | MC020243G | Owner Manual | Miller PIPEPRO XC WELDING SYSTEM (380-400 VOLT MODEL) User manual

Miller PIPEPRO XC WELDING SYSTEM (380-400 VOLT MODEL) User manual
OM-249 143G
2012−08
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Wire Feeder
R
PipePro XC
Welding System
(380-400 Volt Model)
File: MIG (GMAW)
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 specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1-1. Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1-2. Environmental Specifications For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1-4. Wire Feeder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. MIG Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2-1. 40 C (104 F) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2-2. 50 C (122 F) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2-3. 60 C (140 F) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Stick Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3-1. 40 C (104 F) And 50 C (122 F) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3-2. 60 C (140 F) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Equipment Connection Diagram For Self-Shielded Flux Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Equipment Connection Diagram For MIG/RMD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Remote 14 Accessory Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Power Source Remote 14 Wire Feeder Control Receptacle Information . . . . . . . . . . . . . . . . . . . . . . .
5-7. Supplementary Protector CB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Proper Ring Terminal Connection To Work Sense Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Connecting Work Sense Lead And Work Cable To Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Wire Feeder Remote 14 Control Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Wire Feeder Trigger Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Installing And Aligning Wire Guide And Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18. Connecting Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19. Connecting Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-20. Connecting Weld Cable And Work Sense Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-21. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Welding Power Source Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Welding Power Source Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Memory Card Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-2. Using Optional Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Feeder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. PipePro XC Feeder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. PipePro XC Feeder Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. PipePro XC RMD Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. PipePro XC RMD Feeder Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Cleaning Debris From Shielding Gas Filter Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Restoring Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Viewing Software Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Power Source Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Removing Right Side Panel and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Welding Power Source And Feeder Diagnostic Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Troubleshooting Welding Power Source/Wire Feeder Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Welding Power Source Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11. Wire Feeder Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-249 143 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-249 143 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
BATTERY EXPLOSION can injure.
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 Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
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.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D
D
D
D
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-249 143 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-249 143 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2011−10
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
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.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
OM-249 143 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-249 143 Page 6
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du
procédé de soudage, les manipuler avec
précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
OM-249 143 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer
des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
OM-249 143 Page 8
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: Limiter par
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-249 143 Page 9
OM-249 143 Page 10
SECTION 3 − DEFINITIONS
3-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
OM-249 143 Page 11
Disconnect input plug or power before working on machine.
Safe5 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Do not discard product with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Beware of electric shock from wiring.
Safe94 2012−08
Disconnect input plug or power before working on machine.
Safe30 2012−05
Connect Green Or Green/Yellow grounding conductor to ground terminal first.
Connect input conductors (L1, L2, L3) to line terminals.
Safe36 2012−05
Become trained and read the instructions and labels before working on machine.
Safe35 2012−05
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
Safe57 2012−05
OM-249 143 Page 12
?
?
V
A
Consult rating label for input power requirements.
Safe34 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
Do not use one handle to lift or support unit.
Safe31 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe65 2012−06
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
V
V
>5min
= < 60
V
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
Safe43 2012−05
Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
OM-249 143 Page 13
3-2. Miscellaneous Symbols And Definitions
A
Direct Current
(DC)
Alternating
Current (AC)
Off
On
Circuit Breaker
Protective Earth
(Ground)
Negative
Positive
Shielded Metal Arc
Welding (SMAW)
High Frequency General
Line Connection
Gas Metal Arc
Welding (GMAW)
Three Phase Static
Frequency ConverterTransformerRectifier
Increase
U0
Rated No Load
Voltage (Average)
U1
Primary Voltage
Hz
Hertz
S
Suitable for Some
Hazardous
Locations
SD Logo Is A
Trademark Of The
SD−3C, LLC
IP
V
Amperage
Internal Protection
Rating
Gas Input
Notes
OM-249 143 Page 14
U2
I2
Three Phase
VS
Volt Sense Input
Filter
Conventional
Load Voltage
Rated Welding
Current
Single Phase
14
Remote 14
X
%
I1
Voltage
Duty Cycle
Percent
Rated Supply
Current
Flux Cored Arc
Welding (FCAW)
SECTION 4 − SPECIFICATIONS
4-1. Unit Specifications
4-1-1. Welding Power Source Specifications
Input
Power
Three
Phase
Amperage
Range
Setting (CC
Process)
Voltage
Range
Setting (CV
Process)
Welding
Process
Rated Welding
Output
Stick
350 A @ 34 Volts
DC, 100% Duty
Cycle
@ 50 C (122 F)
40 − 350
——
MIG
400 A @ 34 Volts
DC, 100% Duty
Cycle
@ 50 C (122 F)
——
10-39
Flux
Cored
400 A @ 34 Volts
DC, 100% Duty
Cycle
@ 50 C (122 F)
——
10-39
Maximum
OpenCircuit
Voltage
DC
Amperes Input At
Rated Load
Output 50/60 Hz,
Three-Phase
KVA
KW
380 V
400 V
380
400
380
400
23.5
22.7
15.7
15.9
13.2
13.2
27.1
25.7
18.0
18.0
15.5
15.6
27.1
25.7
18.0
18.0
15.5
15.6
80
To appropriately size circuit protection see Section 5-11.
4-1-2. Environmental Specifications For Welding Power Source
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
4-1-3. Dimensions And Weight
Hole Layout Dimensions
A
464 mm (18-1/4 in.)
B
305 mm (12 in.)
C
178 mm (7 in.)
D
565 mm (22-1/4 in.)
E
686 mm (27 in.)
A
B
705 mm
(27-3/4 in.)
C
D
464 mm
(18-1/4 in.)
E
381 mm
(15 in.)
F
10.5 mm (27/64 in.)
4 Holes
F
Ref. 250 702-B
Weight:
56.7 kg (125 lb)
OM-249 143 Page 15
4-1-4. Wire Feeder Specifications
Input Power
Welding Power
Source Type
Wire Feed
Speed Range
Wire Diameter
Range
Welding
Circuit
Rating
IP
Rating*
Overall
Dimensions
PipePro XC
1.3 To 12.7 mpm
(50 To 500 ipm)
0.9 To 1.2 mm
(.035 To .045 in.
100 Volts,
500
Amperes,
100% Duty
Cycle
IP 23
Length: 508 mm
(20 in.)
24 Volts AC
9 Amperes
Max Spool
Weight: 15 kg
(33 lb)
Weight
Width: 203 mm
(8 in.)
15.2 kg
(33-1/2 lb)
Height: 438 mm
(17-1/4 in.)
*This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
4-2. MIG Duty Cycle and Overheating
4-2-1. 405 C (1045 F) Operation
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.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 450 Amperes
60% Duty Cycle At 565 Amperes
6 Minutes Welding
Continuous Welding
Overheating
4 Minutes Resting
A/V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − Ref. 257 025-A
OM-249 143 Page 16
4-2-2. 505 C (1225 F) Operation
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.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 400 Amperes
60% Duty Cycle At 500 Amperes
6 Minutes Welding
Continuous Welding
Overheating
4 Minutes Resting
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − Ref. 257 025-A
4-2-3. 605 C (1405 F) Operation
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.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 300 Amperes
60% Duty Cycle At 375 Amperes
6 Minutes Welding
Continuous Welding
Overheating
4 Minutes Resting
A/V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − Ref. 257 025-A
OM-249 143 Page 17
4-3. Stick Duty Cycle and Overheating
4-3-1. 405 C (1045 F) And 505 C (1225 F) Operation
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,
voltage, wire feed speed, or duty
cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 350 Amperes
Continuous Welding
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − Ref. 257 025-A
4-3-2. 605 C (1405 F) Operation
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,
voltage, wire feed speed, or duty
cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 300 Amperes
Continuous Welding
Overheating
A/V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − Ref. 257 025-A
OM-249 143 Page 18
SECTION 5 − INSTALLATION
5-1. Serial Number And Rating Label Location
The serial number for the power source is located on the front, and the rating information is located on the rear. Suitcase feeder serial number and
rating information is located inside the case near the weld cable. Use rating label to determine input power requirements and/or rated output. For future
reference, write serial number in space provided on back cover of this manual.
5-2. Selecting A Location
Movement
Tipping
2
!
Do not move or operate
unit where it could tip.
3
OR
1
Location
4
1
Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side of
unit.
2
Lifting Handles
Use handles to lift unit.
3
Hand Cart
Use cart or similar device to move unit.
460 mm
(18 in.)
4
!
460 mm
(18 in.)
Line Disconnect Device
Locate unit near correct input power
supply.
Special installation may be
required where gasoline or volatile liquids are present − see NEC
Article 511 or CEC Section 20.
loc_2 3/96 - Ref. 250 702-B
Notes
OM-249 143 Page 19
5-3. Equipment Connection Diagram For Self-Shielded Flux Core
!
Turn Off wire feeder and
welding power source.
!
Use only with the PipePro XC
Power Source.
1
PipePro XC Welding Power
Supply
Weld Cable To Feeder
Electrode Negative
Work Cable To Workpiece
2
1
3
Weld cable and work cable connections to power source.
4
5
Workpiece
Work Sense Lead
Connect work sense clamp to
workpiece.
6
7
8
9
3
9
Gun
Gun Trigger Receptacle
Wire Feeder
Feeder Control Cable
5
2
8
7
6
4
250 769-B
OM-249 143 Page 20
5-4. Equipment Connection Diagram For MIG/RMD
!
Turn Off wire feeder and
welding power source.
!
Use only with the PipePro XC
Power Sources.
1
PipePro XC Welding Power
Supply
Weld Cable To Feeder
Work Cable To Workpiece
2
3
1
Weld cable and work cable connections to power source.
11
4
5
Workpiece
Work Sense Lead
Connect work sense clamp to
workpiece.
6
7
8
9
10
11
2
3
Use of shielding gas is dependant
on wire type.
10
9
Gun
Gun Trigger Receptacle
Wire Feeder
Feeder Control Cable
Gas Hose
Gas Cylinder
.Shielding gas
pressure not to
exceed 90 psi (620 kPa).
8
5
7
6
4
250 770-B
OM-249 143 Page 21
5-5. Remote 14 Accessory Receptacle Information
If a remote control is connected to the Remote 14 receptacle, the unit will automatically adjust output control to a primary/secondary configuration. In
this configuration, the Amperage Adjust knob on the unit becomes the primary and sets the maximum amperage output of the unit. The remote control
becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage Adjust knob setting.
Socket*
A
B
K
J
I
H
C L N
D M
G
E F
A
15 volts DC.
B
Contact closure to A completes 15 volts DC
contactor control circuit.
C
Output to remote control; +10 volts DC.
REMOTE
CONTROL
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from
remote control.
GND
K
Chassis common.
15 VOLTS DC
Ref. 250 702-B
Socket Information
*The remaining sockets are not used.
5-6. Power Source Remote 14 Wire Feeder Control Receptacle Information
Remote 14 Feeder Control
24 volts AC. Protected by supplementary
protector CB2.
C, D
24 volts AC return. Connected to chassis
common. Completes 24 volts AC power supply
circuit to feeder.
J
Isolated RS-485 (+) serial communication signal.
I
Isolated RS-485 (−) serial communication signal.
H
Isolated serial communication common.
POSITIVE VOLT SENSE
G
Positive weld output voltage sense signal.
NEGATIVE VOLT SENSE
F
Negative weld output voltage sense signal.
GND
K, N
SERIAL
COMMUNICATION
*The remaining sockets are not used.
OM-249 143 Page 22
Socket Information
A, B
24 VOLTS AC
Ref. 250 702-B
Socket*
Chassis common.
5-7. Supplementary Protector CB2
1
Supplementary Protector CB2
CB2 protects the 24 volts ac power
supply to the wire feeder.
1
Press button to reset supplementary
protector.
CB2
Ref. 250 702-B
Notes
OM-249 143 Page 23
5-8. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
!
Turn off power before
connecting to weld output terminals.
100 ft (30 m)
or Less
Do not use worn, damaged, undersized, or
poorly spliced cables.
150 ft
(45 m)
Welding
Amperes
Positive
(+)
Negative
(−)
Output Receptacles
Ref. 250 702-B
* This
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
100
2/0 (70)
2/0 (70)
2/0 (70)
2/0 (70)
2/0 (70)
2/0 (70)
2/0 (70
150
2/0 (70)
2/0 (70)
2/0 (70)
2/0 (70)
2/0 (70)
3/0 (95)
3/0 (95)
200
2/0 (70)
2/0 (70)
2/0 (70)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2/0 (70)
2/0 (70)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
2/0 (70)
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
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
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
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
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)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
Ref. S-0007-G 2009−08
OM-249 143 Page 24
5-9. Connecting Weld Output Cables
1
4
Do not place
anything between
weld cable terminal
and copper bar.
2
3
Tools Needed:
3/4 in. (19 mm)
Incorrect Installation
!
Turn off power before connecting to
weld output terminals.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
1 Weld Output Terminal
2 Supplied Weld Output Terminal Nut
3 Weld Cable Terminal
4 Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
803 778-B
weld output terminal and secure with nut so
that weld cable terminal is tight against
copper bar. Do not place anything
between weld cable terminal and copper
bar. Make sure that the surfaces of the
weld cable terminal and copper bar are
clean.
5-10. Connecting To Weld Output Terminals
!
Turn off power before connecting to weld output terminals.
1
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
2
Connect positive weld cable to
Positive (+) weld terminal and
negative (−) cable to Negative
weld terminal.
1
2
Ref. 250 702-B
OM-249 143 Page 25
5-11. Electrical Service Guide
Elec Serv 2011−08
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
60 Hz Three Phase
380
400
27.1
25.7
Time-Delay Fuses 2
30
30
Normal Operating Fuses 3
40
40
10
10
226
(69)
249
(76)
10
10
Input Voltage (V)
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes
Min Input Conductor Size In AWG
1
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-249 143 Page 26
Notes
OM-249 143 Page 27
5-12. Connecting 3-Phase Input Power
3
= GND/PE
Earth Ground
8
10
7
L1
4
L2
6
L3
9
1
2
1
3
4
5
Tools Needed:
L1 L2 L3
6
5/16 in.
input5 2012−05 Ref. 250 702-B
OM-249 143 Page 28
5-12. Connecting 3-Phase Input Power (Continued)
!
!
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 7-7 before
proceeding.
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
Disconnect and lockout/tagout input
power before connecting input
conductors from unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow
conductor to supply grounding
terminal first, and never to a line
terminal.
See rating label on unit and check input
voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Select size and length of conductors using
Section 5-11. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Reinstall side panel on welding power source.
Welding Power Source Input Power
Connections
2
Strain Relief
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief and tighten screws.
3
Welding Power Source Grounding
Terminal
4
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to machine grounding terminal first.
5
Welding Power Source Line Terminals
6
Input Conductors L1, L2, L3
Disconnect
Connections
7
8
9
Device
Input
Power
Disconnect Device (switch shown in the
OFF position)
Disconnect Device Grounding Terminal
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current protection using Section NO TAG (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
Input5 2012−05
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-249 143 Page 29
5-13. Proper Ring Terminal Connection To Work Sense Lead
2
1
3
If work sense lead is cut or broken at end
with ring terminal, be sure that new ring terminal is connected as shown.
1
2
Jacket
Insulated Tape Or Heat-Shrink
Tubing
4
3
Center Conductor
4
Ring Terminal 1/2 in. Opening
Tools Needed:
Ref. 239 780-B
5-14. Connecting Work Sense Lead And Work Cable To Clamp
1
2
3
Work Sense Lead
Work Cable
Clamp
.Be sure that work sense lead
ring terminal is on top of work
cable ring terminal when
connecting to clamp.
Connect work sense lead and work
cable to clamp.
1
3
2
Tools Needed:
1/2 in.
1/2 in.
805 030-A
OM-249 143 Page 30
5-15. Wire Feeder Remote 14 Control Receptacle Information
Remote 14 Feeder Control
Socket Information
A, B
24 volts AC. Protected by supplementary
protector CB2.
C, D
24 volts AC return. Connected to chassis
common. Completes 24 volts AC power supply
circuit to feeder.
J
Isolated RS-485 (+) serial communication signal.
I
Isolated RS-485 (−) serial communication signal.
H
Isolated serial communication common.
POSITIVE VOLT SENSE
G
Positive weld output voltage sense signal.
NEGATIVE VOLT SENSE
F
Negative weld output voltage sense signal.
GND
K, N
24 VOLTS AC
SERIAL
COMMUNICATION
Ref. 250 703-A
Socket*
Chassis common.
*The remaining sockets are not used.
5-16. Wire Feeder Trigger Receptacle Information
Remote 14 Feeder Control
Socket*
Socket Information
1
Trigger
2
Contact closure between 1 and 2 energizes
system output
3
Contact closure between 3 and 4 changes to
alternative schedule
Dual Schedule
Ref. 250 703-A
4
OM-249 143 Page 31
5-17. Installing And Aligning Wire Guide And Drive Rolls
Installing Wire Guide And Drive
Rolls:
1
2
Drive Roll Nut
Drive Roll Carrier
Turn nut one click until lobes of nut
line up with lobes of drive roll carrier.
3
Drive Roll
Slide drive roll onto drive roll carrier.
Turn nut one click.
Repeat procedure for top drive roll.
4
5
Inlet Wire Guide Screw
Inlet Wire Guide
Loosen securing screw. Install inlet
guide so inlet guide screw is
centered in groove in guide, or so tip
is as close to drive rolls as possible
without touching. Tighten screw.
Installing Wire Guide And
Drive Rolls
Aligning Wire Guide And Drive
Rolls:
5
View is from top of drive rolls looking down with pressure assembly
open.
4
6
7
8
9
10
3
Drive Roll Securing Nut
Drive Roll
Wire Guide
Welding Wire
Drive Gear
Turn screw in or out until drive roll
groove lines up with wire guide.
1
Close pressure roll assembly.
2
Only bottom drive roll alignment is
adjustable. Turn adjustment screw
in or out until groove in drive roll
lines up with wire guide as shown.
Cleaning Drive Rolls:
Remove drive rolls, and clean
grooves using a wire brush.
Aligning Wire Guide And Drive Rolls
8
Correct
Incorrect
9
7
6
10
Tools Needed:
3/16 in.
250 764-A
OM-249 143 Page 32
5-18. Connecting Welding Gun
5
2
!
Turn Off wire feeder and
welding power source.
1
2
3
4
5
Gun Securing Knob
Gun Block
Gun Power Pin
Power Pin Groove
Gun Locking Tab
Loosen knob, insert gun end into
block. Position power pin as
close as possible to drive rolls
without touching. Align the gun
power pin groove with the gun
locking tab. Tighten knob.
5
6
7
Gun Trigger Plug
Gun Trigger Receptacle
Connect gun trigger plug to gun
trigger receptacle.
1
Gun Locking Tab In Place
Gun Locking Tab Out Of Place
Internal Side View
4
3
6
7
246 100 / Ref. 250 765-A
OM-249 143 Page 33
5-19. Connecting Shielding Gas
1
2
Gas Hose With 5/8-18
Right-hand Thread Fittings
Shielding Gas Cylinder
.Shielding gas
Rear View
3
4
pressure not to
exceed 90 psi (620 kPa).
3
4
Valve
Flowmeter
Close valve on cylinder when finished welding.
Items 1−4 are user supplied.
2
Tools Needed:
1
5/8 in.
250 767-A
5-20. Connecting Weld Cable And Work Sense Lead
1
User Supplied Weld Cable
Follow wire manufacturer’s recommendations for weld cable polarity.
2
3
From
Wire
Feeder
4
Male Connector
User Supplied Female
Connector
Push female connector over male
connector, and turn 1/4 turn clockwise.
4
Work Sense Lead
Connect work sense lead to terminal on rear of feeder.
2
1
3
250 768-A
OM-249 143 Page 34
5-21. Installing And Threading Welding Wire
Installing Wire And Adjusting
Hub Tension:
1
2
.Hold wire tightly
to keep it from
unraveling.
Retaining Nut
Hub Tension Adjustment
Screw
Remove retaining ring, and install
spool so hub pin fits spool hole. Reinstall retaining nut.
Adjust tension nut so only a slight
force is needed to turn spool.
Threading Welding Wire:
3
Pressure Assembly
Adjustment Knob
Lay gun cable out straight.
Open pressure assembly, hold wire
tightly, and cut off end. Push wire
through guides into gun.
Close and tighten pressure assembly. Press Jog switch until wire
comes out gun.
3
Feed wire against wooden surface,
and tighten knob so wire does not
slip.
Cut off wire, and close door.
1
2
6 in.
(150 mm)
Pull and hold wire; cut off end.
Tighten
Clockwise
WOOD
Tools Needed:
Ref. 250 764-A
OM-249 143 Page 35
SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Amps
Indicates average amperage while welding and holds the value for 10 seconds at end of weld.
Arc Control
The adjustment of arc cone width and arc characteristics in the SS FCAW, MIG and RMD processes.
Increasing Arc Control value increases the arc cone width and subsequently effects the arc length (end of
electrode to workpiece).
CO2
100% CO2 shielding gas.
C20-C25
Gas mixture of mainly Argon and 20-25% CO2.
Dual Schedule
A two position switch which attaches to (or incorporated in) the gun handle that can be used to change weld
parameters during the MIG welding processes. The gun trigger operates as a standard trigger. Dual Schedule is
always activated.
EXX10
Stick welding electrode type. EXXX1 or EXXX2 are typically used on this setting (cellulosic electrode).
EXX16/EXX18
Stick welding electrode type. EXXX3 through EXXX8, or stainless are typically used on this setting (low
hydrogen type electrode).
FCAW (Flux Cored Arc
Welding)
Flux cored arc welding is a continuous electrode that is fed into the arc and depends on shielding gas from
either an external source or is generated from the decomposition of gas forming ingredients contained in the
electrode’s core.
Hot Start
Increases output amperage at start of weld. This helps eliminate electrode sticking during arc initiation.
Jog
Method for feeding wire without contactor or gas valve being energized.
Metal Core
MIG wire consumable = carbon metalcore.
MIG (GMAW)
Also referred to as solid wire welding. An arc welding process which joins metals by heating them with an arc.
The arc is between a continuously fed filler metal (consumable) electrode and the workpiece. Externally
supplied gas or gas mixtures provide shielding.
Preflow
The time that the shielding gas flows prior to an arc start.
Postflow
The time that the shielding gas continues to flow after the arc has been terminated.
Process
A selection made for MIG, RMD, Stick, or Flux Core (FCAW).
Purge
Method for energizing the gas valve(s) to purge gas lines before welding and to preset gas pressure at the regulator.
RMD
RMD stands for Regulated Metal Deposition, a precisely controlled short-circuit transfer process. Benefits of
RMD are well suited to root pass welding on pipe, improves gap filling and spatter reduction. Provides less heat
input into the workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge materials.
Settings for RMD include Arc Length, Wire Speed and Arc Control.
Solid
MIG wire consumable = carbon solid.
Stick (SMAW)
Stick (SMAW) welding uses a flux covered consumable electrode that produces a shielding gas and slag to
shield the arc and molten weld puddle.
Synergic
Synergic refers to the unit’s ability to use preprogrammed parameters to determine the actual pulse settings of
Peak Amperage, Background Amperage, Pulse Frequency, and Pulse Width at any specific wire feed speed
setting. This is a characteristic used in RMD processes.
Trigger Hold
This feature reduces welder fatigue by allowing continuous welding without holding the trigger.
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 10 seconds hold value at end of weld.
Wire
Selection of wire diameter for MIG and RMD processes. Wire diameter selections include 0.9, 1.0 and 1.2 mm.
WFS
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In
Pulse and RMD, adjusting wire feed speed also increases power level on wire electrode (one knob control).
OM-249 143 Page 36
6-2. Welding Power Source Controls
1
2
3
4
5
SAVE
STICK
9
FEEDER
ELECTRODE
6
EXX10
LOAD
AMPS
7
CARD
EXX16
EXX18
8
1
2
3
Stick Process Select Button
AMPS Display
Amperage Adjustment Knob
248 795-A
4
5
6
Feeder Select Button
Memory Card Program Save Button
Memory Card Program Load Button
7
8
9
Memory Card In Use Indicator Light
Electrode Select Button
Memory Card Busy Indicator Light
OM-249 143 Page 37
6-3. Welding Power Source Operation Description
Stick Process Select
Button
Adjustable DIG
Press and release this button to activate the stick welding process controls. The STICK text below the button
illuminates as well as the active stick electrode type text and the swoosh above the amperage adjustment knob.
The operator must select the desired stick electrode type and adjust the amperage knob to the appropriate
setting within a range from 40 to 350 amps.
Press STICK button for two seconds to enter the adjustable DIG mode. The amperage display will show the
DIG setting with the right most decimal point illuminated. DIG can be adjusted over a range of 0 to 99 with 40
as the default. Setting for EXX10 and EXX16/EXX18 are independent (each has its own DIG setting).
Pressing any button exits the DIG adjustment mode.
.DIG can be adjusted while welding.
Adjustable Hot Start
When in the Adjustable DIG mode, press the STICK button to enter the adjustable Hot Start mode. The
amperage display will show the Hot Start setting. Hot Start can be adjusted over a range of 0.0 to 2.0 with
1.0 as the default. The higher the number, the longer hot start takes to ramp down to the welding amperage
set on the unit.
AMPS Display
This display shows the amperage setting. The average amperage is displayed while welding and continues to
appear for 10 seconds after the welding arc is extinguished.
Amperage Adjustment
Knob
Use this knob to set a desired amperage setting for the stick welding process. Rotating the knob clockwise
increases amperage and counter−clockwise decreases amperage. Amperage adjustment is active when the
swoosh above the knob is illuminated. If a remote control is connected to the Remote 14 receptacle, the unit will
automatically adjust output control to a primary/secondary configuration. In this configuration, the Amperage
Adjustment knob on the unit becomes the primary and sets the maximum amperage output of the unit. The
remote control becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage
Adjustment knob setting.
Feeder Select Button
Press and release the Feeder Button on the power source to activate weld processes from an attached wire
feeder. The FEEDER text below the button illuminates. Refer to the feeder operation section.
Memory Card Program
Save Button
Press and release this button to save all stored operator settings as a setup configuration file to the memory
card. The busy LED will illuminate to indicate the save operation is in progress. In addition, whenever the SAVE
button is pressed a file named SUMMARY is updated on the MEMORY Card. This file has a Status Summary,
Firmware Revisions, and Fault History. The file can be read using a computer equipped with a memory card
reader. This information can be used for maintenance schedules or troubleshooting.
Memory Card Program
Load Button
Press and release this button to load a previously saved configuration file from the memory card in the card slot.
This operation allows restoring previously saved operation settings on the card to a different system. The busy
LED will illuminate to indicate the load operation is in progress.
Memory Card In Use
Indicator Light
The memory CARD text will illuminate when custom MIG or RMD type weld process data is currently being
used from the memory card.
Electrode Select Button
Press and release this button to select the desired stick electrode type (EXX10 or EXX16/EXX18). The text
above or below the button will illuminate for the active electrode type. This button is only active with the stick
welding process selection and only then will text for the electrode type selection illuminate
Memory Card Busy
Indicator Light
The memory card busy LED illuminates during the following conditions: storage/retrieval of operator settings,
usage of custom MIG type weld process, and software upgrades.
OM-249 143 Page 38
6-4. Memory Card Slot
1
Memory Card Slot
1
6-4-1. Description
Memory Card Slot
This is the memory card slot. Amemory card can be inserted into the slot and used for storing and retrieving
operator settings, providing custom MIG type weld process data, and loading software updates to the unit. If the
power source has multiple users, each user may use a card to store and load their own personal settings. Push
in and release the card edge to eject it from the slot.
6-4-2. Using Optional Memory Card
Memory Card Insertion
Lift and hold memory card access cover open. Insert memory card into slot, push card all the way into the slot,
and then release. Close the memory card access cover
Optional Program Card
Operation
Insert the optional program card into the slot. Select wire feeder by pressing the FEEDER button on the power
source. Select the weld process by pressing the MIG PROCESS button on the feeder front panel until the
desired process is illuminated. The memory CARD text will illuminate on the power source front panel as well as
on the feeder front panel to indicate that the optional program is being used from the memory card. If applicable,
select the wire diameter by pressing the MIG Wire button on the feeder front panel until the desired wire
diameter is illuminated. Remove the memory card to revert to standard operation.
.Some optional program cards only support a single wire diameter, in this case, only that diameter will
illuminate.
Software Update Card
(System Software Update)
Insert the software update card into the slot. Perform software update by pressing and holding the LOAD button
on the power source front panel until ”UPd” appears on the 7−segment LED display. Wait fo the software update
to complete (approximately two minutes). Remove card.
.During the software update, the displays on both the power source and feeder front panels may display
“H99” or "H98" as well as the "UPd" or go blank for a period of time. This is normal during a sofware update. Do
not remove the memory card until the software update has completed. Do not turn off the power source until the
software update has completed.
OM-249 143 Page 39
6-5. Feeder Operation
1
Feeder Units Switch
Switch position up for inches per
minute.
1
Switch position down for meters per
minute.
Ref. 250 764-A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-249 143 Page 40
6-6. PipePro XC Feeder Controls
1
10
ACCU-POWER
3
2
VOLTS WIRESPEED
AMPS
4
5
7
6
8
ARC
CONTROL
9
TRIGGER
HOLD
CARD
JOG
AUTOJOG
249 063-A
1
2
3
4
Power Control Button
Volts Display
Wirespeed/Amps Display
Voltage Adjustment Knob
5
Wirespeed Adjustment Knob
8
Jog Button
6
Arc Control Button
9
Memory Card Indicator Light
7
Trigger Hold Button
10 Accu−Power Indicator Light
OM-249 143 Page 41
6-7. PipePro XC Feeder Operation Description
Power Control Button
Press this button to power up or power down the wire feeder. When powered down, the feeder is still in a
standby mode allowing it to power up when the power control button is pressed. When in the standby mode, a
decimal point will flash in the lower right corner of the wire speed display.
VOLTS Display
This display shows the voltage setting for self-shielded FCAW (10.0 to 39.0 volts). “VOLTS” will be illuminated
below the display. The actual voltage is displayed while welding and continues to appear for 10 seconds after
the welding arc is extinguished.
Wirespeed/Amps Display
This display shows the wire speed setting within a range of 1.3 to 3.8 meters per minute (50 to 150 inches per
minute). When showing wire speed, “WIRESPEED” will be illuminated below the display. While welding, the
display will show weld amperage and “AMPS” will be illuminated below the display. Measured amperage just
prior to the end of the welding operation will appear in the display for 10 seconds after the welding operation.
The display will then revert back to wire speed.
Voltage Adjustment Knob
Use this knob to adjust the desired voltage setting within a range of 10.0 to 39.0 volts. Rotating the knob clockwise increases the voltage and counter-clockwise decreases the voltage. Voltage adjustment is active when the
swoosh above the knob is illuminated.
Wirespeed Adjustment
Knob
Use this knob to adjust wire speed within a range of 1.3 to 3.8 meters per minute (50 to 150 inches per minute).
Rotating the knob clockwise increases the wire speed and counter-clockwise decreases the wire speed. Wire
speed adjustment is active when the swoosh above the knob is illuminated.
Arc Control Button
Press and release this button to adjust arc control. When in arc control adjustment, the volts display will show
the setting and the wire speed display will show “Ind”. Rotating the volts knob clockwise increases the arc control and counter-clockwise decreases the arc control. The adjustable range is 0 to 99 with a default setting of 50.
Pressing any button exits the arc control adjustment feature.
.When using dual schedule, arc control settings for each dual schedule switch position are independent (each
switch position has its own arc control setting). Arc control can be adjusted while welding
Trigger Hold Button
Press and release this button to enable/disable the trigger hold feature. The LED will illuminate above this button
to indicate when trigger hold is active. When trigger hold is active, the gun trigger must be pressed and held
after the arc is established for a minimum of one half second, but not more than six seconds. Releasing the gun
trigger activates the trigger hold function. To stop welding, press and release the gun trigger.
Jog Button
Press and hold this button to jog wire from the feeder. Rotate the wire speed adjustment knob to change the jog
speed within a range of 1.3 to 12.7 meters per minute (50 to 500 inches per minute). Rotating the knob clockwise increases jog speed and counter-clockwise decreases job speed. Release the button to stop the jog operation and the display will return to the initial wire speed setting. The default setting is 12.7 meters per minute
(500 inches per minute).
Auto Jog
Pressing and releasing the jog and trigger hold buttons simultaneously will activate the auto jog function.
This feature will automatically jog a preset amount of wire. The volts display will count down in 0.01 meter
(0.1 feet) decrements starting at the preset wire length. A default preset wire length is set at 3.0 meters
(10.0 feet), but the length can be changed within a range of 1.5 to 9.1 meters (5.0 to 30.0 feet) using the
volts adjust knob. Rotating the knob clockwise increases wire length and counter-clockwise decreases wire
length. The volts display will show the set wire length for a short time after making any desired adjustment.
If no further changes are made to the wire length after one second the unit will resume the countdown
display. Jog speed can also be adjusted within a range of 1.3 to 12.7 meters per minute (50 to 500 inches
per minute) using the wire feed speed adjust knob and the wire feed speed display will show the current job
speed setting.
Memory Card Indicator
Light
“CARD” will illuminate when a memory card with a custom weld program is inserted into the card reader slot.
Accu-Power Indicator
Light
“ACCU−POWER” will illuminate when the Accu-Power feature is enabled on the system.
OM-249 143 Page 42
6-8. PipePro XC RMD Front Panel Controls
1
14
3
2
4
5
8
6
9
7
11
12
10
13
256 280-A
1
Power Control Button
2
Volts/Arc Length Display
3
Wirespeed/Amps Display
4
Volts/Arc Length Adjustment Knob
5
6
7
8
9
Wirespeed Adjustment Knob
Purge Button
Arc Control Button
Trigger Hold Button
Jog Button
10
11
12
13
14
FCAW Process Select Button
MIG Process Select Button
Wire Diameter Select Button
Memory Card Indicator Light
Accu-Power Indicator Light
OM-249 143 Page 43
6-9. PipePro XC RMD Feeder Operation Description
Power Control Button
Press this button to power up or power down the wire feeder. When powered down, the feeder is still in a
standby mode allowing it to power up when the power control button is pressed. When in the standby mode, a
decimal point will flash in the lower right corner of the wire speed display.
Volts/Arc Length Display
This display shows the voltage setting for MIG, Gas-Shielded and Self-Shielded processes (10.0 to 39.0 volts)
and it shows the arc length for the RMD process (−3.0 to +3.0 in 0.1 increments with 0 as nominal). “VOLTS”
will be illuminated below the display when showing voltage. “ARC LENGTH” will be illuminated when showing
arc length. The actual voltage is displayed while welding and continues to appear for 10 seconds after the welding arc is extinguished.
Wirespeed/Amps Display
This display shows the wire speed setting within the range based on the MIG process selected (see Table 4-1).
When showing wire speed, “WIRESPEED” will be illuminated below the display. While welding, the display will
show weld amperage and “AMPS” will be illuminated below the display. Measured amperage just prior to the
end of the welding operation will appear in the display for 10 seconds after the welding operation. The display
will then revert back to wire speed.
Voltage/Arc Length
Adjustment Knob
Use this knob to adjust the desired voltage setting (10.0 to 39.0 volts) or arc length setting (−3.0 to +3.0 in 0.1
increments with 0 as nominal) depending on the type of MIG process selected. Rotating the knob clockwise
increases the voltage and counter-clockwise decreases the voltage. Voltage/arc length adjustment is active
when the swoosh above the knob is illuminated.
Wirespeed Adjustment
Knob
Use this knob to adjust wire speed within the range based on the MIG process selected (see Table 4-1). Rotating the knob clockwise increases the wire speed and counter-clockwise decreases the wire speed. Wire speed
adjustment is active when the swoosh above the knob is illuminated.
Purge Button
Press and hold this button to purge shielding gas lines prior to welding or to preset gas pressure at the regulator.
Release the button to stop the purge operation.
Timed Purge
Arc Control Button
Pressing and releasing the purge and trigger hold buttons simultaneously will activate the timed purge
function. The volts/arc length display will count down in 1 second decrements starting at the preset amount
of time. A default preset time period is set at 30 seconds, but the time can be changed within a range of 5 to
60 seconds using the volts/arc length adjust knob. Rotating the knob clockwise increases time and
counter-clockwise decreases time. The volts/arc length display will show the set time after making any
desired adjustment. If no further changes are made to the time period, after one second the unit will resume
the count down display.
Press and release this button to adjust arc control. When in a FCAW process (gas-shielded or self-shielded) or
short circuit MIG process, the volts display will show the setting and the wire speed display will show “Ind”. Rotating the volts knob clockwise increases the arc control and counter-clockwise decreases the arc control. The
adjustable range is 0 to 99. For a FCAW process the default is 50. For a short circuit MIG process the default
setting is 25.
When in an RMD process, the volts display will show the setting and the wire speed display will show “Arc”.
Rotating the volts knob clockwise increases the arc control and counter-clockwise decreases the arc control.
Pressing any button exits the arc control adjustment feature.
.When using dual schedule, arc control settings for each dual schedule switch position are independent (each
switch position has its own arc control setting). Arc control can be adjusted while welding
Trigger Hold Button
Press and release this button to enable/disable the trigger hold feature. The LED will illuminate above this button
to indicate when trigger hold is active. When trigger hold is active, the gun trigger must be pressed and held
after the arc is established for a minimum of one half second, but not more than six seconds. Releasing the gun
trigger activates the trigger hold function. To stop welding, press and release the gun trigger.
Jog Button
Press and hold this button to jog wire from the feeder. Rotate the wire speed adjustment knob to change the jog
speed within a range of 1.3 to 12.7 meters per minute (50 to 500 inches per minute). Rotating the knob clockwise increases jog speed and counter-clockwise decreases job speed. Release the button to stop the jog operation and the display will return to the initial wire speed setting. The default setting is 12.7 meters per minute
(500 inches per minute).
Auto-Jog
OM-249 143 Page 44
Pressing and releasing the jog and trigger hold buttons simultaneously will activate the auto jog function.
This feature will automatically jog a preset amount of wire. The volts display will count down to 0.01 meter
(0.1 feet) decrements starting at the preset wire length. A default preset wire length is set at 3.0 meters
(10.0 feet), but the length can be changed within a range of 1.5 to 9.1 meters (5.0 to 30.0 feet) using the
volts adjust knob. Rotating the knob clockwise increases wire length and counter-clockwise decreases wire
length. The volts display will show the set wire length for a short time after making any desired adjustment.
If no further changes are made to the wire length, after one second the unit will resume the countdown display. Jog speed can also be adjusted within a range of 1.3 to 12.7 meters per minute (50 to 500 inches per
minute) using the wire feed speed adjust knob and the wire feed speed display will show the current job
speed setting.
6-9.
PipePro XC RMD Feeder Operation Description (Continued)
FCAW Process Select
Button
Press this button to select the desired FCAW process. Possible selections include “NO GAS” (self-shielded
FCAW) or “GAS” (gas-shielded FCAW). The process type text will illuminate to show the active process.
MIG Process Select
Button
Press this button to select the desired short circuit MIG process. Possible selections include MIG, RMD METAL
CORE, RMD SOLID C15−C25, RMD Solid 100% CO2. The process type text will illuminate to show the selected wire diameter.
Wire Diameter Select
Button
Press this button to select the electrode diameter used for the selected MIG process. Possible selections include 0.9 mm, 1.0 mm and 1.2 mm. The wire diameter text will illuminate to show the selected wire diameter.
Memory Card Indicator
Light
“CARD” will illuminate when a memory card with a custom weld program is inserted into the power source card
reader slot.
Accu-Power Indicator
Light
“ACCU−POWER” will illuminate when the Accu-Power feature is enabled on the system.
Pre/Post Flow
Pressing and releasing the arc control and purge buttons simultaneously will activate the adjustable preflow and
postflow function. When this occurs, the volts display will show “PrE” and the wire speed display will show a
time setting in 0.1 seconds increments. Adjustment of the preflow time is made by turning the wire speed knob.
Adjustable range is 0 to 5 seconds in 0.1 second increments.
Turning the voltage knob clockwise will access adjustable postflow. The voltage display will show “PSt” and the
wire speed meter will show a time setting in 1 second increments. Adjustment of the postflow time is made by
turning the wire speed knob. Adjustable range is 0 to 60 seconds in 1 second increments.
Table 4-1. FCAW And MIG Process Parameters
Process
Wire Size (mm)
WFS Range (mpm)
Self-Shielded FCAW
Various
1.3−5.1
Gas-Shielded FCAW
Various
1.3−12.7
0.9
1.3−12.7
1.0
1.3−12.7
1.2
1.3−12.7
*1.2
1.9−5.7
0.9
2.5−8.9
1.0
2.5−7.6
1.2
1.9−6.4
0.9
3.8−6.4
1.0
3.8−6.4
1.2
2.5−5.1
MIG
RMD METAL CORE C20 GAS
RMD SOLID C15−C25
RMD SOLID 100% CO2
*This program is optimized for metal core wire.
Notes
OM-249 143 Page 45
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
!
n = Check
~ = Clean
Disconnect power before maintaining.
l = Replace
Every
3
Months
l Unreadable Labels
~ Weld Terminals
nl Weld Cable
n 14-Pin Cord
n Gas Hose and Fittings
n Gun Cable
l Cracked Electrode
Holder Parts
nl Gun Cables
Every
6
Months
l Cracked Parts
Or
~ Inside Unit
~ Drive Rolls
7-2. Blowing Out Inside of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 250 702-B
OM-249 143 Page 46
7-3. Cleaning Debris From Shielding Gas Filter Fitting
!
Disconnect power
maintaining.
1
Shielding Gas Filter Fitting
before
Remove fitting from gas valve on
back panel of feeder.
Rear View of Feeder
Blow compressed air through the
threaded male end of fitting to dislodge debris from internal mesh
screen.
.Replace
fitting if blowing compressed air through fitting does
not clear obstructions.
1
Reinstall fitting into gas valve.
Tighten fitting to 200 in. lbs (22.6 Nm).
Tools Needed:
3/4 in.
FILT
Ref. 804 004-A / 805 128-A
Notes
OM-249 143 Page 47
7-4. Restoring Factory Defaults
Full System
A full factory reset can be accomplished by pressing STICK and FEEDER buttons on the power source simultaneously for more than four seconds. The
display will show “rSt” and then go to dashes when the reset is complete.
7-5. Viewing Software Revision
Pressing the EXX10, EXX16/EXX18 and a hidden button about 1 inch below the FEEDER button on the power source simultaneously will display the
Software Revision.
7-6. Power Source Calibration Procedure
Only qualified persons should install, operate, maintain, and repair this unit.
1.
Calibrated DC voltmeter and clamp-on DC ammeter (e.g. Fluke 337)
2.
Calibration Card
3.
Shorting cable (2/0)
1.
Disconnect cables from all output studs.
2.
Turn on power to the welding system.
3.
Insert Calibration card.
4.
5.
6.
7.
a.
Lift and hold memory card access cover open.
b.
Insert memory card into slot (push card all the way into slot and then release).
c.
Close memory card access cover.
d.
Power source will display CAL.
Calibrate voltage as follows:
a.
Connect voltmeter from + stud to − stud.
b.
Press FEEDER button on the power source front panel. Open circuit voltage should now be present from + stud to the − stud.
c.
Using the knob on the power source front panel, set the display voltage to the measured value on the voltmeter.
d.
Press FEEDER button on the power source front panel to end the voltage calibration.
e.
Power source will display CAL.
Calibrate amperage as follows:
a.
Connect shorting cable from + stud to − stud.
b.
Attach clamp-on ammeter around shorting cable.
c.
Press STICK button on the power source front panel. Amperage should now be flowing in the shorting cable.
d.
Using the knob on the power source front panel, set the display amperage to the measured value on the ammeter.
e.
Press STICK button on the power source front panel to end the amperage calibration.
f.
Power source will display CAL.
g.
Disconnect shorting cable.
Remove Calibration card as follows:
a.
Lift and hold memory card access cover open.
b.
Push in and release memory card to eject card.
c.
Grasp memory card and remove from slot.
d.
Close memory card access cover.
Turn off power to the welding system.
OM-249 143 Page 48
7-7. Removing Right Side Panel and Measuring Input Capacitor Voltage
!
Turn Off welding power
source, and disconnect
input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
Turn Off welding power source, and
disconnect input power.
1
1
Right Side Panel
To remove panel, remove screws
securing panel to unit.
2
Relinking Board PC10
3
Voltmeter
Measure the dc voltage across the
screw terminals on PC10 as shown
until voltage drops to near 0 (zero)
volts.
.If the capacitor voltage does not
2
drop to near zero after several
minutes, use a bleeder resistor
of between 25 and 1000 ohms,
at least 5 watts, #16 AWG 1000
volts DC insulating rating wire
to discharge the capacitor(s) .
3
4
Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
Proceed with job inside unit. Reinstall
right side panel when finished.
4
+ lead to lower right terminal, −
lead to upper right terminal
Typical Bleeder Resistor
25 to 1000 ohms,
5 watt resistor
#16 AWG 1000 volts DC
insulation rating, approx
3 in. (76 mm) leads
Tools Needed:
5/16 in.
Ref. 250 702-B
OM-249 143 Page 49
7-8. Welding Power Source And Feeder Diagnostic Help Codes
H
0
1
Display Example
Display Code
Fault
Description
H01
Primary Power Circuit Over Current
Indicates a malfunction in the primary power circuit. If this code
appears on the display, contact the nearest Factory Authorized
Service Agent.
H02
Temperature Sensor Malfunction
H03
Secondary Circuit Over Temperature
H05
Primary Circuit Over Temperature
Indicates right side of unit has overheated. Unit has shutdown
to allow fans to lower right side temperature. Operation will
continue after unit is within normal temperature range.
H08
Output Over Voltage Malfunction
Indicates secondary power circuit is malfunctioning. If this code
appears on the display, contact the nearest Factory Authorized
Service Agent.
H09
Primary Power Circuit Current Detect Malfunction
Indicates primary power circuit is malfunctioning. If this code
appears on the display, contact the nearest Factory Authorized
Service Agent.
H10
Primary Power Circuit Control Malfunction
Indicates primary power circuit is malfunctioning. If this code
appears on the display, contact the nearest Factory Authorized
Service Agent.
H11
Primary Bus Capacitor Voltage Imbalance
Indicates primary power circuit is malfunctioning. If this code
appears on the display, contact the nearest Factory Authorized
Service Agent.
H12
Primary Input Line Voltage Malfunction
Indicates input primary line voltage is too low or power source
is incorrectly linked.
Increase primary line voltage to at least 90% of specified
nominal voltage.
H13
Voltage Sense
H25
Duty Cycle
H26
Button Stuck Power Source
H31
Stuck Contactor Stick
Indicates stuck remote contactor in Stick mode. Fault will clear
when foot pedal or control device contactor is released.
H40
Tach
Indicates tach error. Check feeder drive housing and wire spool for
obstructions. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.
H42
Motor
Indicates motor error. Check feeder drive housing and wire
spool for obstructions. If this code continues to appear on the
display, contact the nearest Factory Authorized Service Agent.
H44
Motor Low Bus
Indicates input primary line voltage is too low or power source
is incorrectly linked.
Increase primary line voltage to at least 90% of specified
nominal voltage.
If this code continues to appear on the display, contact the
nearest Factory Authorized Service Agent.
H45
Button Stuck Feeder
Indicates button is stuck on the feeder upon feeder power up.
Fault will clear when button is released.
OM-249 143 Page 50
Indicates thermal protection circuitry is malfunctioning. If this
code appears on the display, contact the nearest Factory
Authorized Service Agent.
Indicates left side of unit has overheated. Unit has shutdown to
allow fans to lower left side temperature. Operation will continue
after unit is within normal temperature range.
System cannot measure output voltage. Make sure work sense
lead is connected between feeder and work. If this code
continues to appear on the display, contact the nearest Factory
Authorized Service Agent.
Indicates duty cycle limit exceeded. Output stops and the cooling
fan will run. Wait 15 minutes for unit to cool. Reduce amperage,
voltage, wire feed speed, or duty cycle before welding.
Indicates button is stuck on the power source upon start up.
Fault will clear when button is released.
7-8.
Welding Power Source And Feeder Diagnostic Help Codes (Continued)
H46
Trigger Stuck
Indicates trigger stuck fault. Fault will clear when trigger is released.
H48
Trigger Fault
Indicates trigger was held too long in trigger jog (the lesser of
60 seconds or 30 ft (9.1 m) of wire.
H60
Memory Card Fault
Indicates unable to read memory card. Faulty memory card or
wrong format.
H61
File Read Error
Indicates faulty file on memory card.
H62
File Write Error
Indicates full or faulty memory card.
H63
Invalid File
Indicates an invalid file on memory card. The system was able
to read the file; however, the contents of the file were invalid.
Remove card or press any button to clear error.
H64
Memory Card Locked
Indicates a save was attempted to a locked card. This refers to
the physical switch on the memory card. Unlock the memory
card and try again. Try a different memory card. Remove card
or press any button to clear error. If this code continues to appear on the display, contact the nearest Factory Authorized
Service Agent.
H65
Read Only File
Indicates a save was attempted to a file that has been marked
read-only. Check with the appropriate person to see if the attributes are read only for a reason (the attributes can be altered
using a PC). Use a different card. Remove card or press any
button to clear error.
H66
No Memory Card Detected
Indicates no memory card detected when a memory card operation was attempted. Insert a card or press any button to clear
error. Try a different memory card. If this code continues to
appear on the display, contact the nearest Factory Authorized
Service Agent.
H67
Unsupported Memory Card Format
Indicates that a memory card with an unsupported format was
detected. Reformat card, or try a different memory card.
H70
Weld Library
H98
Serial Communication Loss
H99
Serial Communication Malfunction
Indicates missing/incomplete weld library in power source.
Weld library must be loaded from memory card.
Indicates serial communication was initially made and is now
malfunctioning. Check wire feeder/power source control cable
connection and tighten if necessary. May appear normally during firmware updates. If this code continues to appear on the
display, contact the nearest Factory Authorized Service Agent.
Indicates serial communication is malfunctioning. Check wire
feeder/power source control cable connection and tighten if
necessary. May appear normally during firmware updates. If
this code continues to appear on the display, contact the
nearest Factory Authorized Service Agent.
OM-249 143 Page 51
7-9. Troubleshooting Welding Power Source/Wire Feeder Issues
If the welding power source and wire feeder are NOT responding after everything is connected, follow the items listed below before contacting the
nearest factory-authorized service agent:
Welding power source is plugged in and there is no power after turning on unit.
S
If unit is directly connected to a line disconnect box or plugged into a receptacle from a line disconnect box, be sure that the line disconnect switch
or main breaker is in the ON position.
Wire does not feed from wire feeder to end of gun.
S
Check to see if wire diameter matches the groove size of the drive rolls.
S
Check if tension on drive rolls is too loose or too tight.
S
Check if gun liner is the correct size for the wire size.
S
Check if contact tip is correct size for the wire size, and that end of contact tip is not plugged.
S
Check if gun end is fully inserted into wire drive housing at feeder, and knob is tightened down to secure gun end.
S
Ensure gun cable is not coiled.
Weld is not consistent from one welding application to another.
S
Be sure that work clamp is connected to a clean, paint-free area of pipe; otherwise, grind an area if necessary to make a good work connection.
S
Keep work clamp as close as possible to joint being welded.
S
Check if work sense lead is connected to the feeder, and that work connection is secure. Check for any frayed wires at work end of work sense
lead that may prevent a good connection.
S
Be sure that work sense lead is separated from weld cables.
S
Be sure gun angle during welding is straight in to 15 degrees back at joint.
S
Follow recommended settings in Operation section of manual to select a starting point for welding.
S
Recommended joint preparation and fit-up is 1/32-1/16 in (0.8-1.6 mm) land and a 1/8 in (3.2 mm) root opening.
Porosity in weld bead.
S
Check shielding gas supply that there is enough gas and supply is turned on.
S
Check shielding gas flow rate at regulator.
S
Check that gas pressure to the wire feeder does not exceed 90 psi (621 kPa).
S
Check all shielding gas fitting and tighten if necessary.
S
Remove gun end from wire drive housing and check condition of O-rings. Replace any worn or missing O-rings.
S
Check power pin end of gun and tighten with a wrench.
S
Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end.
S
Check and clean shielding gas nozzle on gun.
S
Shield joint from wind.
Trouble feeding wire when welding. Check drive rolls and wire guides to make sure they match the wire style
and size.
S
Check drive roll tension and readjust if necessary.
S
Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end.
S
Check if hub tension at wire spool is too tight or too loose and readjust if necessary.
S
Be sure that welding gun cable is as straight as possible from wire feeder to workpiece.
S
Check if contact tip is correct size for the wire size, and that end of contact tip is not plugged.
S
Check if gun liner is the correct size for the wire size and liner is not dirty or damaged. Clean or replace gun liner if necessary.
OM-249 143 Page 52
7-10. Welding Power Source Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-12).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-12).
Check for proper input power connections (see Section 5-12).
No weld output; meter display On.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On.
Check voltmeter/ammeter Help displays.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 5-8).
Clean and tighten all weld connections.
Check work sense lead. Straighten any coiled cables.
No 24 volts AC output at Remote 14
Feeder receptacle.
Reset supplementary protector CB2.
When remote control is connected to Check remote control switch and potentiometer resistances.
unit output is always on.
7-11. Wire Feeder Troubleshooting
!
Disconnect power before troubleshooting.
Trouble
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Remedy
Check cable connections. Check cables for continuity, and repair or replace cables if necessary.
Wire feeder is on, display does not light Check and reset circuit breaker at welding power source.
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
Electrode wire feeding stops, or feeds
erratically during welding.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure.
Change to correct size drive roll (see Table 9-1).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Motor runs slowly.
Check for correct input voltage.
Wire feeder displays light up, feeder
jogs, purges, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
When triggered, wire feeds but no gas,
no contactor.
If the welding arc does not establish in 2 seconds after the gun trigger is activated the unit will feed
wire, but turns off contactor and gas valve. If the gun trigger is still activated after 60 seconds or 30 ft
(9.1 m) of wire was fed from the gun, the wire will stop feeding.
OM-249 143 Page 53
SECTION 8 − ELECTRICAL DIAGRAM
Figure 6-1. Circuit Diagram For Welding Power Source
OM-249 143 Page 54
248 664-E
OM-249 143 Page 55
Figure 6-2. Circuit Diagram For XC And XC RMD Wire Feeders
OM-249 143 Page 56
249 146-C
OM-249 143 Page 57
SECTION 9 − PARTS LIST
. Hardware is common and
7
not available unless listed.
8
9
2
11
28
17
25
18
26
5
21
22
4
6
13
14
20
3
15
19
24
23
26
12
10
16
27
1
254 860-B
Figure 7-1. Main Assembly
OM-249 143 Page 58
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly
... 1 ..........
... 2 ..........
... 3 ..........
... 4 ..........
... 5 ..........
................
................
... 6 ..........
... 7 ..........
... 8 ..........
... 9 ..........
. . . 10 . . . . . . . . . .
. . . 11 . . . . . . . . . .
. . . 12 . . . . . . . . . .
. . . 13 . . . . . . . . . .
. . . 14 . . . . S1 . .
. . . 15 . . . FM1 . .
. . . 16 . . . . . . . . . .
. . . 17 . . . . T1 . .
. . . 18 . . . . T2 . .
. . . 19 . . C1,C2 .
. . . 20 . . C3,C4,
C5,C6 .
. . . 21 . . . . . . . . . .
. . . 22 . . . . . . . . . .
. . . 23 . . . . . . . . . .
. . . 24 . . . . . . . . . .
. . . 25 . . . . . . . . . .
. . . 26 . . C8,C11
. . . 27 . . . PC4 . .
. . . 28 . . . CB2 . .
249230
248870
248844
249213
249217
248743
010467
249085
249848
187234
249881
249882
206270
234271
203310
244920
222728
255287
249027
249392
230273
. . Base Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, LH w/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, RH w/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Front Panel Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rear Panel Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Clamp Cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket Assy, Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Sheet, Insulator Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Tgl 3PST 40A 600VAC SCR Term Wide Tgl . . . . . . . . . . . . . . . . . . . . .
. . Fan, Muffin 24VDC 3000 RPM 255 CFM 6.378 Mtg Holes . . . . . . . . . . . . . . .
. . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Xfmr, HF 380/400 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Xfmr, Control E&I 380V W/23V & 34V CT 415VA . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor, Polyp Film .5 UF 1000 VRMS 10% . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
234104
233489
183827
185214
185992
199840
222488
240621
083432
..
..
..
..
..
..
..
..
..
4
1
1
2
2
4
2
1
1
Capacitor, Elctlt 2700 UF 450 VDC Can 2.52 Dia . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . . . .
+ 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-249 143 Page 59
. Hardware is common and
not available unless listed.
2
6
3
1
4
5
254 871-A
Figure 7-2. Base Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Base Assembly
................
... 1 ..........
. . . 2 . . L3,L4 .
... 3 ..........
... 4 ..........
... 5 ..........
... 6 ..........
249230
250139
250374
218566
250144
250238
253523
..
..
..
..
..
..
..
Base Assemby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductor, DI−DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasket, Inductor Mounting E70 Ferrite Core . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount, Vibration 50 Duro Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Output Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
4
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-249 143 Page 60
. Hardware is common and
not available unless listed.
LH
11
3
10
4
6
7
1
5
9
2
8
13
21
25
RH
22
12
18
17
24
23
7
14 15 16
20
19
254 861-B
Figure 7-3. Windtunnel Assembly LH And RH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Windtunnel Assembly LH And RH
. . . . . . . . . . . . . . . . . . . . . . . . . . . Windtunnel, LH w/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . 179902 . . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . 204165 . . . . Heat Sink, Rect Dual Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . D1,D2
D3,D4 201531 . . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . 232296 . . . . Resistor/Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . 179826 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . 181853 . . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . 179276 . . . . Bushing, Snap−In Nyl 1.000 ID X 1.375 Mtg Hole Cent . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . 010493 . . . . Bushing, Snap−In Nyl .625 ID X .875 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . HD1 . . 168829 . . . . Transducer, Current 1000A Module Max Open Loop . . . . . . . . . . . . . . . . . . .
. . . 10 . . . RT2 . . 209223 . . . . Thermistor, NTC 30k ohm @ 25 Deg C 18.00 in Lead . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . 180778 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . Windtunnel, RH w/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . 248750 . . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . 179930 . . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 PM1,PM2**240144 . . . . Kit, Transistor IGBT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . SR1 . . 249052 . . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . RT1 . . 173632 . . . . Thermistor, NTC 30k Ohm @ 25 Deg C 12.00In Lead . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 236287 . . . . Plugs, W/Leads (IGBT Gates) (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 115091 . . . . . Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 115094 . . . . . Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
4
2
1
1
1
4
1
1
1
1
1
1
1
1
1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
**This kit contains two modules and instructions. Be sure to follow the field kit instructions when performing the
installation.
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-249 143 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Windtunnel Assembly LH And RH (Continued)
...
...
...
...
...
...
...
...
...
17
18
19
20
21
22
23
24
25
..........
..........
. . . CT1 . .
..........
. . . . L2 . .
. . . . L1 . .
. . . W1 . .
..........
..........
025248
153403
181271
177547
180029
180026
180270
145743
181925
. . . . Stand−Off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−In Nyl .750 ID X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . .
. . . . Xfmr, Current 500 Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−In Nyl Ct−Mount 1.093 Mtg Hole . . . . . . . . . . . . . . . . . . . . .
. . . . Stabilizer, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Contactor, Def Prp 40A 3P 24VAC Coil w/Boxlug . . . . . . . . . . . . . . . . . . . . .
. . . . Lug, Univ W/Scr 600V 2−14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Stabilizer Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2
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-249 143 Page 62
. Hardware is common and
not available unless listed.
3
2
13
6
8
7
4
14
1
5
16
12
11
10
15
9
12
11
10
254 862-A
Figure 7-4. Front Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-4. Front Panel Assembly
................
... 1 ..........
... 2 ..........
... 3 ..........
... 4 ..........
... 5 ..........
... 6 ..........
... 7 ..........
249213
248777
234344
236830
249764
248795
213134
147195
..
..
..
..
..
..
..
..
Front Panel Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Assy, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, SD Card Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door, SD Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overlay, Front Interface UI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Encoder 1.670 Dia X .250 ID Push On w/Spring . . . . . . . . . . . . . . . . . . .
Nut, 375−27 .54hex .25H Nyl Flange .62D . . . . . . . . . . . . . . . . . . . . . . . . . . .
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-249 143 Page 63
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-4. Front Panel Assembly (Continued)
...
...
...
...
...
...
...
...
...
8
9
10
11
12
13
14
15
16
. . . . . . . . . . 181245
. . . . . . . . . . 182707
. . . . . . . . . . 180735
. . . . . . . . . . 186621
. . . . . . . . . . . 181169
. . PC12 . 244477
. . . PC3 . . 248006
. . . PC5 . . 253640
. . . . . . . . . . 170391
..
..
..
..
..
..
..
..
..
Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, UI w/ProgrAM PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Feeder And Remote Interface . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ MS Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
2
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-249 143 Page 64
. Hardware is common and
2
not available unless listed.
3
6
4
1
5
7
254 863-A
Figure 7-5. Control Board Bracket Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-5. Control Board Bracket Assembly
................
... 1 ..........
. . . 2 . . . PC2 . .
. . . 3 . . . PC1 . .
. . . 4 . . . PC9 . .
. . . 5 . . . FM2 . .
... 6 ..........
... 7 ..........
249085
248768
249643
248607
253621
183918
083147
198122
..
..
..
..
..
..
..
..
Bracket, Assembly Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Circuit Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Inverter Control 400V Potted . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Process Control w/Program Potted . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, VS Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, Fan 24VDC 3000 RPM 43 CFM w/10 Ohm Resistor . . . . . . . . . . . . . .
Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . . . .
Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
4
3
+ 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-249 143 Page 65
. Hardware is common and
not available unless listed.
20
22
6
16
17
10
18
11
14
7
12
40
30
15
4
41
28
5
19
9
13
8
53
42
29
43
58
23
52
21
3
31
51
50
34
32 / 33
39
57
44
27
43
35
24
56
49
48
47
2
38
55
54
46
45
37
25 / 26
36
1
254 973-A
Figure 7-6. XC Wire Feeder And XC RMD Wire Feeder Assemblies
OM-249 143 Page 66
Quantity
Item
No.
Dia.
Mkgs.
... 1 ..............
... 2 ..............
... 3 ..............
... 4 ..............
... 5 ..............
... 6 ..............
... 7 ..............
... 8 ..............
... 9 ..............
. . . 10 . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . .
. . . 28 . . C1.C2 . . . . .
. . . 29 . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . .
. . . 31 . . . SR1 . . . . . .
. . . 32 . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . .
....................
....................
. . . 35 . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . . . . .
Model
Part
No.
248814
249160
249057
249056
246453
124778
166071
079634
151828
254959
170075
248631
222159
010224
234073
054263
237188
234074
144172
172076
605308
079625
092865
248823
248744
249068
249080
177360
207678
210133
035704
248817
249822
248820
131204
115094
239737
249848
249062
248816
235608
235607
237843
172918
231211
058424
250514
250455
250458
208076
Description
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
300794 300844
Figure 7-6. XC Wire Feeder And XC RMD Wire
Feeder Assemblies
Case, Control Feeder Machined SC 12 Blk . . . . . . . . . . . . . . . . . . 1 . . . .
Chassis, Control Box Suitcase 12 w/Stand−Off . . . . . . . . . . . . . . . 1 . . . .
Motor, Right Angle 23.6VDC 28:3:1 Gear Ratio . . . . . . . . . . . . . . 1 . . . .
Panel, Motor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Housing, Adapter Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Knob, T 2.000 Bar w/.312−18 Stud 1.000 Lg . . . . . . . . . . . . . . . . . 1 . . . .
Lever, Mtg Pressure Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
Pin, Cotter Hair .062 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Carrier, Drive Roll w/Components 24 Pitch . . . . . . . . . . . . . . . . . . . 1 . . . .
Knob, Tension Adjust Assy w/Cupped Washer MM350 . . . . . . . . 1 . . . .
Spring, Torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Pin, Spring CS .187 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Screw, Thumb Stl .250−20 X .500 Pld Type P . . . . . . . . . . . . . . . 1 . . . .
Lock, Pin Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Clamp, Power Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 . . . . . . . . . . . . . . . . . 1 . . . .
Carrier, Drive Roll W/Components Keyed 24 Pitch . . . . . . . . . . . . 1 . . . .
Ring, Rtng Ext .500 Shaft X .035 Thk . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Washer, Wave .500 ID x 0.750 OD x.015t Stl Lbs . . . . . . . . . . . . . 2 . . . .
Key, Stl .1215/.1230 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Insulator, Motor Suitcase 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Panel Assy, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Assy, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Assy, Weld w/Strn Rel & Dinse . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Capacitor, Elctlt 20000 uf 45 VDC Can 1.40 Dia . . . . . . . . . . . 2 . . . .
Insulator, Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Bracket, Capacitor Support SC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Rectifier, Integ Bridge 40. Amp 800V . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Insulator, Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Receptacle, Banana Jack Blk 10−32 Binding Post . . . . . . . . . . . . 1 . . . .
Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Shroud, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Hub, Spool 12 Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Nut, Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Knob, Brake Adjust (Diecast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Washer, Anti−Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
Washer, FBR (Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Insulator, Spool Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Stiffener, Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Panel, Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
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-249 143 Page 67
Quantity
Item
No.
Dia.
Mkgs.
. . . 49 . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . . .
. . . 53 . . . PC1 . . . . . .
. . . 54 . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . . .
. . . 56 . . . . . . . . . . . . . .
. . . 57 . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . . .
....................
....................
....................
....................
....................
....................
Model
Part
No.
217932
226819
134834
220805
248425
228165
222181
182445
214860
211989
079607
250071
250073
250075
250077
250693
Description
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
300794 300844
Figure 7-6. XC Wire Feeder And XC RMD Wire
Feeder Assemblies (Continued)
Switch, Rocker SPST .4VA 28VDC On−None−Off .187 Ter . . . . . 1
Valve, 12VDC 1way .750−14 Thd 2mm Orf 100 PSI . . . . . . . . . . . . . . . . .
Hose, SAE .187 ID X .410 OD x coil . . . . . . . . . . . . . . . . . . . . . . . .
....
Nut, 750−14 NPS 1.48 hex .41H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Motor Control w/Prg . . . . . . . . . . . . . . . . . . . . . . 1
Grommet, SCR No 8 Panel Hole .312 X .343 .515 High . . . . . . . 4 . . . .
Grommet, SCR No 8/10 Panel Hole .281 Sq .031 High . . . . . . . 8 . . . .
Nut, Conduit 1.000 NPT Pld 1.688 OD X .200 Thk . . . . . . . . . . . . 1 . . . .
Nut, Ln Pg21 1.26 hex .14H Nickel Plated Brass . . . . . . . . . . . . . . 1 . . . .
Fitting, w/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Drive Roll .045 VK−Gr 2 Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Plugs, W/Leads (Front Interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Plugs, W/Leads (Cap Bank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Plugs, W/Leads (Volt Sense) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Plugs, W/Leads (Dc Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Plugs, W/Leads (Gas Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
1
1
1
4
8
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-249 143 Page 68
. Hardware is common and
not available unless listed.
10
11
5
2
6
7
11
9
3
1
8
4
7
XC RMD Wire Feeder Front Panel
(300844)
8
XC Wire Feeder Front Panel
(300794)
254 974-A
Figure 7-7. XC And XC RMD Wire Feeder Front Panels
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
Description
300794 300844
Figure 7-7. XC And XC RMD Wire Feeder Front Panels
... 1 ..............
... 2 ..............
... 3 ..............
... 4 ..............
... 5 ..............
... 6 ..............
... 7 ..............
... 8 ..............
....................
....................
. . . 9 . . . PC2 . . . . . .
. . . 10 . . . PC2 . . . . . .
. . . 11 . . . . . . . . . . . . . .
249051
248745
249063
249066
256280
248751
174991
250268
115093
080328
248486
248746
253556
..
..
..
..
..
..
..
..
..
..
..
..
..
Panel, Front w/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, Front w/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer 1.250 Dia X .250 ID w/Spring Clip−.21 . . . . . . . . . . 2 . . . .
Cable, Trigger 18 In Dual Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Rcpt w/Skts, Free Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
Circuit Card Assy, UI w/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Circuit Card Assy, UI w/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasket, Front Pnl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
1
1
1
2
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-249 143 Page 69
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2012
(Equipment with a serial number preface of MC or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
* Spoolmate Spoolguns
provide instructions on the warranty claim procedures to be
followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to an
International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
Miller’s True Blue Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
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 2012-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
 2012 Miller Electric Mfg. Co.
2012−01
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