Miller | LK410002G | Owner Manual | Miller PIPEWORX 400 SYSTEM W/COOLER (230/460, 575 VOLT) User manual

Miller PIPEWORX 400 SYSTEM W/COOLER (230/460, 575 VOLT) User manual
OM-236 891E
2009−10
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
TIG (GTAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
Multiprocess Welding
Description
Arc Welding Power Source
Wire Feeder
PipeWorx 400
Welding System
(230/460 And 575 Volt Models)
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
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2. MIG Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-3. Stick And TIG Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-4. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-5. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-6. Remote 14 Accessory Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-7. Turning On Remote 14 Receptacle Control For Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-8. Changing Wire Feed Speed From Inches Per Minute (IPM) To
Meters Per Minute (MPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-9. Remote 14 Wire Feeder Control Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-10. Supplementary Protector CB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-11. 115 Volts AC Single Receptacle And Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-12. Lifting Eye On Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-13. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-14. Selecting Input Voltage (230/460 Volt Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-15. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-16. Installing Optional Handles, Running Gear And Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3-17. Assembling And Installing Cable Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-18. Weld Output Terminals And Selecting Cable Sizes* Recommended For PipeWorx 400 . . . . . . . . . . . 27
3-19. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-20. Proper Ring Terminal Connection To Volt Sense Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-21. Connecting Volt Sense Lead And Work Cable To Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-22. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder
On Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-23. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder
On Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3-24. Wire Feeder Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3-25. Gun Trigger Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3-26. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-27. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs . . . . . . . . . . . . . . . . . . 35
3-28. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-29. Typical Connection Diagram For Stick (SMAW) Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-30. Typical Connection Diagram For Two Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside
Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3-31. Typical Connection Diagram For One Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside
Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-32. Typical Connection Diagram For Liquid-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power
Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TABLE OF CONTENTS
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Welding Power Source Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Stick Process Selection Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. TIG Process Selection Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. MIG Process Selection Setup Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. MIG Process Selection Setup Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Wire Feeder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Postflow Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Wire Feeder Left Side Active Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Wire Feeder Right Side Active Setup Example (Dual Feeder Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Wire Feeder Non-MIG Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Wire Feeder Timed Purge Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Wire Feeder Auto Jog Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Basic Parameters For PipeWorx 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Restoring Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Viewing Software Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Power Source Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460 Volt Models . . . . . . .
5-7. Removing Right Side Panel and Measuring Input Capacitor Voltage In
575 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Cooler Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Welding Power Source And Feeder Diagnostic Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Troubleshooting Welding Power Source/Wire Feeder Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Welding Power Source Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Wire Feeder Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Cooler Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
42
42
44
49
50
51
52
53
56
57
58
59
60
61
62
65
66
66
66
67
67
67
69
70
71
72
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75
76
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2009−08
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-236 891 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-236 891 Page 2
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect ImplantedMedical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-236 891 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-236 891 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2009−08
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
OM-236 891 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-236 891 Page 6
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques
et autres implants médicaux doivent rester
à distance.
D Les porteurs d’implants médicaux doivent consulter
leur médecin et le fabricant du dispositif avant de s’approcher
de la zone où se déroule du soudage à l’arc, du soudage
par points, du gougeage, de la découpe plasma
ou une opération de chauffage par induction.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles
de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
OM-236 891 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
OM-236 891 Page 8
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global
Engineering Documents (téléphone : 1-877-413-5184, site internet :
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
Internet : www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-236 891 Page 9
OM-236 891 Page 10
SECTION 3 − INSTALLATION
3-1. Specifications
A. Welding Power Source Specifications
Input
Power
Amperage
Range
Setting
(CC Process)
Voltage
Range
Setting
(CV Process)
350 A @ 34
Volts DC,
100% Duty
Cycle
40 − 350
TIG
350 A @ 34
Volts DC,
100% Duty
Cycle
10-350
MIG
400 A @ 44
Volts DC,
100% Duty
Cycle
——
Flux
Cored
400 A @ 44
Volts DC,
100% Duty
Cycle
——
Welding
Process
Rated Welding
Output
Stick
Three
Phase
Maximum
OpenCircuit
Voltage
DC
Amperes Input At
Rated Load Output
60 Hz, Three-Phase
KVA
KW
230 V
460 V
575 V
230
460
575
230
460
575
——
36.8
22.5
18.9
14.8
18.0
19.0
13.7
13.7
13.8
——
36.8
22.5
18.9
14.8
18.0
19.0
13.7
13.7
13.8
10-44
53.6
31.1
26.0
21.5
24.7
25.9
20.0
19.9
19.7
10-44
53.6
31.1
26.0
21.5
24.7
25.9
20.0
19.9
19.7
90
To appropriately size circuit protection see Section 3-13.
B. Dimensions And Weight
Hole Layout Dimensions
E
A
A
19-1/2 in. (495 mm)
B
16-7/8 in. (424 mm)
C
31-3/4 in. (806 mm)
31-3/4 in.
(806 mm)
C
D
16 in. (406.4 mm)
E
5/16-18 in. UNC thread
28-1/2 in.
(724 mm)
B
Weight
D
225 lb (102 kg)
19-1/2 in.
(495 mm)
805 142-A
OM-236 891 Page 11
C. Wire Feeder Specifications
Input Power
Welding Power
Source Type
Wire Feed
Speed Range
Wire Diameter
Range
Welding
Circuit
Rating
IP
Rating
Overall
Dimensions
PipeWorx 400
50 To 780 ipm
(1.3 To 19.8
mpm)
.035 To .062 in
(0.9 To 1.6 mm)
100 Volts,
750
Amperes,
100% Duty
Cycle
IP 21
Length: 29 in.
(737 mm)
24 Volts AC
11 Amperes
Max Spool
Weight: 60 lb
(27 kg)
Width: 19 in.
(483 mm)
Weight
Single
Dual
65 lb
(30 kg)
90 lb
(41 kg)
Height: 14 in.
(356 mm)
D. Cooler Specifications
Input Power
Pump
115 Volts AC
Blower
115 Volts AC
Overall Dimensions
Coolant Capacity
Length: 29 in.
(737 mm)
Width: 19-3/8 in.
(492 mm)
Height: 12 in.
(305 mm)
3 gal (11.4 L)
E. Coolant Chart
Low Conductivity Coolant No. 043 810*
Coolant
*Coolant 043 810 protects to -37° F (-38° C) and resist algae growth.
NOTICE − Use of any coolant other than that listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.).
OM-236 891 Page 12
Weight
Net
Wet Weight
108 lb
(49 kg)
133 lb
(60 kg)
3-2. MIG Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 400 Amperes
60% Duty Cycle At 565 Amperes
6 Minutes Welding
Continuous Welding
Overheating
4 Minutes Resting
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 240 110-A
3-3. Stick And TIG Duty Cycle and Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage,
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
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − 240 110-A
OM-236 891 Page 13
3-4. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
3-5. Selecting a Location
Movement
!
Tipping
Do not move or operate
unit where it could tip.
1
OR
2
Location
3
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3
18 in.
(460 mm)
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.
18 in.
(460 mm)
loc_2 3/96 − Ref. 805 142-A
OM-236 891 Page 14
3-6. 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.
. The Remote 14 receptacle is factory set to be active in TIG mode only. As an option, this receptacle may also be enabled in Stick mode (see
Section 3-7).
Socket*
A
B
K
J
Socket Information
A
15 volts DC.
B
Contact closure to A completes 15 volts DC
contactor control circuit.
C
Output to remote control; +10 volts DC.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from
remote control.
K
Chassis common.
15 VOLTS DC
I
H
C L N
D M
G
E F
805 143--A
REMOTE
CONTROL
GND
*The remaining sockets are not used.
OM-236 891 Page 15
3-7. Turning On Remote 14 Receptacle Control For Stick
!
1
Stick
Remote
Off
Stick
Remote
On
ON
ON
1 2
1 2
Turn Off welding power
source, disconnect input
power, and check voltage
on input capacitors according to Section 5-6 before
proceeding.
When this control is active and a
current/contactor
control
is
connected to the Remote 14
receptacle on the power source
front panel, the contactor and
primary/secondary
amperage
control will function in both TIG and
Stick modes.
1
2
User Interface Board
Dip Switch
Remove feeder and side mount
cable hangers from top of unit, if
applicable.
2
Remove top cover from power
source.
Move number 2 switch to the up
position (on stick side). Use a small
screwdriver to move switch, if
necessary.
Reinstall cover.
Replace side mount cable hangers
and feeder to top of unit, if
applicable.
Tools Needed:
5/16 in.
805 288-A
OM-236 891 Page 16
3-8. Changing Wire Feed Speed From Inches Per Minute (IPM) To
Meters Per Minute (MPM)
3
2
!
Turn Off welding power
source, disconnect input
power, and check voltage
on input capacitors according to Section 5-6 before
proceeding.
1
2
3
PipeWorx Feeder
Operator Interface Board
Dip Switch
Remove feeder wrapper.
Move number 1 switch (top switch)
to the ON position. Use a small
screwdriver to move switch, if
necessary.
Reinstall wrapper.
1
Rear View Of
Wire Feeder
Front Panel
Tools Needed:
5/16 in.
805 298-A / 805 429-A
OM-236 891 Page 17
3-9. Remote 14 Wire Feeder Control Receptacle Information
Remote 14 Feeder Control
Socket*
8, 12
24 VOLTS AC
ÌÌ
SERIAL
COMMUNICATION
POSITIVE VOLT SENSE
NEGATIVE VOLT SENSE
Ref. 805 144-A / Ref. 048 286-B
*The remaining sockets are not used.
OM-236 891 Page 18
GND
Socket Information
24 volts AC. Protected by supplementary
protector CB2.
1,4
24 volts AC return. Connected to chassis
common. Completes 24 volts AC power supply
circuit to feeder.
6
Isolated RS-485 (+) serial communication signal.
3
Isolated RS-485 (−) serial communication signal.
5
Isolated serial communication common.
14
Positive weld output voltage sense signal.
11
Negative weld output voltage sense signal.
2,10
Chassis common.
3-10. Supplementary Protector CB2
1
Supplementary Protector CB2
CB2 protects the 24 volts ac power
supply to the wire feeder (see
Section 3-9).
Press button to reset supplementary
protector.
1
TOWIREFEEDER
CB2
TIGGASIN
MIGOUTPUT
805 298-A
OM-236 891 Page 19
3-11. 115 Volts AC Single Receptacle And Supplementary Protector
1
2
115 V 10 A AC Receptacle
(Cooler Power Supply Only
When Power Source Is On)
Supplementary Protector CB1
CB1 protects single 115 volt AC
receptacle.
Press button to reset supplementary
protector.
2
USE 2/0 CABLE MINIMUM
1
805 143-A
OM-236 891 Page 20
3-12. Lifting Eye On Power Source
!
Turn Off welding power
source, disconnect input
power.
1
Lifting Eye
The wire feeder allows access to
the lifting eye on the power source.
The entire welding system as
shown with cable hangers, cooler
with coolant, dual feeder, and
running gear can be lifted with the
lifting eye.
The control cable must be
disconnected from the feeder. Use
of a lifting strap may be necessary.
1
Total weight is approximately 525 lb
(238 kg) excluding welding guns
and cables.
. Be sure that wire spools,
cables and gas bottles are
removed before lifting the
welding system.
805 293-A
OM-236 891 Page 21
3-13. Electrical Service Guide
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
230
460
575
61
34
29
Time-Delay Fuses 2
80
40
30
Normal Operating Fuses 3
100
50
40
6
8
10
148
(45)
386
(118)
402
(122)
8
10
10
Input Voltage (V)
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes
1
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-236 891 Page 22
3-14. Selecting Input Voltage (230/460 Volt Models Only)
!
. Be sure to reinstall all four screws securing relinking board in place.
Turn Off welding power
source, disconnect input
power, and check voltage
on input capacitors according to Section 5-6 before
proceeding.
Check input voltage available at
site.
1
Voltage Selection View
Window
Check voltage selected in unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
1
2
3
4
5
6
Relinking Board PC10 In 230
VAC Position
Mounting Screws
Receptacle RC8 (Connection
For 230 VAC Input Power)
Receptacle RC7 (Connection
For 460 VAC Input Power)
Relinking Board PC10 In 460
VAC Position
Move relinking board as needed
and connect plug PLG4 (in unit) to
RC8 or RC7 according to input
power voltage.
3 4
2
3
5
6
Tools Needed:
5/16 in.
Ref. 805 142-A / 805 145-B
OM-236 891 Page 23
3-15. Connecting Input Power
3
= GND/PE
Earth Ground
!
Installation must meet all
National and Local Codes −
have only qualified persons
make this installation.
!
Disconnect and lockout/tagout input power before connecting input conductors
from unit.
!
Always connect green or
green/yellow conductor to
supply grounding terminal
first, and never to a line
terminal.
4
7
. Right
side panel can be
removed to allow attaching
primary cable even with
handles installed.
2
1
2
3
4
L1
3
L2
L3
6
1
5
5
6
Input Power Cord.
Disconnect Device (switch
shown in the OFF position)
Green Or Green/Yellow
Grounding Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And
L3)
Disconnect Device Line
Terminals
Connect green or green/yellow
grounding conductor to disconnect
device grounding terminal first.
Connect input conductors L1, L2,
and L3 to disconnect device line
terminals.
7
Over-Current Protection
Select type and size of over-current
protection using Section 3-13
(fused disconnect switch shown).
8
Strain Relief Connector Clamp
Obtain and install proper connector.
9
8
1
Contactor W1
Select size and length using
Section 3-13. Connect as shown in
illustration.
Close and secure door on
disconnect
device.
Remove
lockout/tagout device, and place
switch in the On position.
9
Tools Needed:
L1 L2 L3
5/16 in.
805 146-A
OM-236 891 Page 24
3-16. Installing Optional Handles, Running Gear And Cooler
Tools Needed:
1/2 in.
5/16 in.
!
Turn Off welding power source,
disconnect input power.
1
2
3
4
5
Running Gear 234 359
Cooler
Wheel 163 463 (2)
Flat Washer 602 250 (4)
Retaining Ring 121 614 (2)
Install wheels on cylinder tray as shown.
9
Set cooler on running gear.
. If not installing a cooler, set power
source on running gear.
6
7
8
11
6 7
8
12
Flat Washer 602 240 (4)
Lock Washer 602 211 (4)
Screw 601 944 (4)
Secure cooler to running gear using
supplied flat washers, lock washers and
screws.
14
10
9
9
Power Source
Set power source on cooler.
11
Secure power source to cooler using
same hardware that was used to secure
cooler to running gear.
2
10
11
12
13
14
13
15
Cylinder Support Bracket
Bushing 170 647 (2)
Bushing 004 214 (1)
Screw 128 237 (4)
Chain 188 441 (2)
Install cylinder support bracket to rear of
power source and secure with supplied
screws. Install bushings and chains.
16
17 20 21
19
15 Handle Bracket
16 Handle (2)
17 Tube Cap (4)
2
18
Install tube caps into ends of handles.
Remove 5 screws above louvered panel
on front of power source.
4
24
3
23 22
6
1
5
Attach handle bracket to front of power
source using the 5 screws previously
removed.
Remove 2 screws on the side of the cover
on front of power source.
7
8
18 Screw 234 483 (2)
Start supplied upper handle mounting
screws into handles by hand on each side
of power source.
19 Screw 604 535 (2)
20 Lock Washer 602 211 (2)
21 Flat Washer 602 240 (2)
Start supplied screws, lock washers and
flat washers into handle bracket by hand
on each side of power source.
22 Screw 604 535 (4)
23 Lock Washer 602 211 (4)
24 Flat Washer 602 240 (4)
Start supplied lower handle mounting
screws, lock washers and flat washers
into handles by hand on each side of
power source.
Tighten all handle hardware.
805 302-A / 805 292-A
OM-236 891 Page 25
3-17. Assembling And Installing Cable Hanger
1
2
3
1
Bracket
Tube Cap (4)
Cable Holder Tube (2)
Install caps in tubes.
Assemble cable holder tubes to
bracket using supplied hardware.
Place cable holder assembly on top
of power source or cart and set wire
feeder on cable hanger.
2
3
Tools Needed:
3/8 in.
7/16 in.
805 148-B / 805 141-A
OM-236 891 Page 26
3-18. Weld Output Terminals And Selecting Cable Sizes* Recommended For PipeWorx 400
!
ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
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
Stick
(+)
* This
200 ft
(60 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)
Work TIG (−)
805 143-A
250 ft
(70 m)
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-236 891 Page 27
3-19. Connecting Weld Output Cables
1
4
Do not place
anything between
weld cable terminal
and copper bar.
2
Tools Needed:
3
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.
OM-236 891 Page 28
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.
3-20. Proper Ring Terminal Connection To Volt Sense Lead
2
1
3
If volt 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 10 ga
4
Ring Terminal 1/2 in. Opening
Tools Needed:
Ref. 239 780-B
3-21. Connecting Volt Sense Lead And Work Cable To Clamp
1
2
3
Volt Sense Lead
Work Cable
Clamp
. Be
Tools Needed:
sure that volt sense
lead ring terminal is on top of
work cable ring terminal when
connecting to clamp.
1/2 in.
1/2 in.
Connect volt sense lead and work
cable to clamp.
1
3
2
805 030-A
OM-236 891 Page 29
3-22. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder
On Power Source
4
2
7
1
9
6
5
3
9
11
8
10
805 144-B
!
Do not put feeder where welding
wire hits cylinder.
!
Do not move or operate equipment
when it could tip.
1
Welding Power Source
2
Wire Feeder
3
MIG Connection
4
Positive (+) Weld Cable
5
Feeder Control Cable Connection
OM-236 891 Page 30
6
Gas Hose
7
Gas Cylinder
Connect 14-pin plug to rear of power
source, and connect 14-socket plug to rear
of wire feeder. Connect one end of weld
cable to weld terminal on rear of power
source. Connect remaining end of weld
cable to wire feeder drive housing. Connect
one end of gas hose to regulator/flowmeter
on gas cylinder and connect remaining end
of gas hose to gas solenoid connector on
rear of feeder or Y-hose for dual wire feeder.
8
Work (−) Weld Cable
. Attach
volt sense lead to work
clamp and attach work clamp as close
to arc as possible.
9
Volt Sense Cable
10 Workpiece
11 Welding Gun
3-23. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder
On Cart
8
1
7
13
5
2
6
3
4
10
13
10
9
12
11
805 317-B
!
Do not put feeder where welding
wire hits cylinder.
!
Do not move or operate equipment
when it could tip.
1
Welding Power Source
2
Wire Feeder
3
Feeder Cart
4
Composite Cable
5
MIG Connection
6
Positive (+) Weld Cable
7
Gas Hose
8 Gas Cylinder
Locate end of composite cable where gas
hose extends out of sleeve approximately
50 inches (1270 mm). This end of the
composite cable connects to the power
source. Connect 14-pin plug to rear of
power source, and connect 14-socket plug
to rear of wire feeder. Connect one end of
weld cable to weld terminal on rear of power
source and secure cable in clamp block on
rear panel. Connect remaining end of weld
cable to wire feeder drive housing and
secure cable in clamp block on feeder
base. Connect one end of gas hose to
regulator/flowmeter on gas cylinder and
connect remaining end of gas hose to gas
solenoid connector on rear of feeder or
Y-hose for dual wire feeder.
9
Work (−) Weld Cable (2/0 minimum)
. Attach
volt sense lead to work
clamp and attach work clamp as close
to arc as possible.
10 Volt Sense Cable
11 Workpiece
12 Welding Gun
13 Strain Relief Clamp
OM-236 891 Page 31
3-24. Wire Feeder Rear Panel Connections And Rotating Drive Assembly
1
2
14-Pin Control Cable
Shielding Gas Valve Fittings
Requires fitting with 5/8-18
right-hand
threads.
Connect
customer-supplied gas hose.
3
4
5
6
7
3
9
8
To rotate the drive assembly,
loosen drive assembly rotation
knob, rotate drive assembly, and
tighten knob.
8
9
4
Weld Cable Terminal
Jumper Weld Cable From
Right Side Drive Assembly
(Dual Model Only)
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
Rating Label Location
Volt Sense Terminal
5
1
2
2
9
6
7
Tools Needed:
9/16, 5/8 in.
3/16 in.
805 155-A / Ref. 804 766-A / 802 825-A
OM-236 891 Page 32
3-25. Gun Trigger Receptacle
1
2
Left Gun Trigger Receptacle
RC2
Right Gun Trigger Receptacle
RC3 (Dual Model Only)
Connect gun trigger plug to
appropriate receptacle on feeder.
1
2
805 154-A
OM-236 891 Page 33
3-26. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spools. Adjust tension nuts so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Adjust
Rear
Rolls
Pressure
Indicator
Scale
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Tools Needed:
Drive Rolls
3/16, 5/64 in.
Back Of Gun
15/16, 3/8 in.
End Of Liner
. For best wire feeding performance,
be sure that the outlet cable has the proper size liner for the welding wire size being used. Also, when the gun is installed,
the liner extending from the back of the
gun should be as close to the drive rolls
as possible, without touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
. For soft wire or small diameter stainless steel wire, reduce drive roll pressure
on the rear roll to half that of the front rolls.
. To adjust
drive roll pressure, hold
nozzle about 2 in (51 mm) from
nonconductive surface and press gun
trigger to feed wire against surface.
Tighten knob so wire does not slip. Do not
overtighten. If contact tip is completely
blocked, wire should slip at the feeder
(see pressure adjustment above).Cut
wire off. Close cover.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 804 743-A
OM-236 891 Page 34
3-27. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs
A. Ideal Setup
1
2
5
3
1
6
4
5
2
3
4
805 289-B
1 Welding Power Source
2 Composite Cable
3 Work Cable
4 Volt Sense Lead
The volt sense lead must be used to
provide an accurate voltage feedback
signal to the welding system. Use of this
lead is critical for stable welding
performance.
5
Wire Feeder
6
Workpiece
This arrangement is an ideal setup for
supporting separate voltage feedback to
the welding power sources. The most
accurate voltage sensing may not be
achieved due to voltage drops in the
workpiece.
This
may
require
compensation in the welding parameters.
OM-236 891 Page 35
B. Bad Setup
1
2
5
3
4
6
805 290-B
1
2
3
4
5
Welding Power Source
Composite Cable
Work Cable
Voltage Sensing Lead
Wire Feeder
OM-236 891 Page 36
6
Workpiece
This arrangement is a bad setup due to
sensing leads being directly in the current
flow path of the welding arc. Interaction
between welding circuits will affect voltage
drop in the workpiece. The voltage drop
across the workpiece will not be measured
correctly for the voltage feedback signal.
Voltage feedback to the welding power
sources will not be correct at either sense
lead and result in poor arc starts and arc
quality.
3-28. Arranging Welding Cables To Reduce Welding Circuit Inductance
1
2
3
4
5
6
1
Ideal
5
2
3
Welding Power Source
Composite Cable
Work Cable
Volt Sense Lead
Wire Feeder
Workpiece
The method used to arrange cables has
a significant affect on welding
performance. As an example,
Pro-Pulse and RMD welding processes
can produce high welding circuit
inductance depending on cable length
and arrangement. This can result in
limited current rise during droplet
transfer into the welding puddle.
The electrode sense and volt sense
leads are contained in the feeder control
cable and are enabled for all processes.
The volt sense lead automatically
compensates for work cable voltage
drop when connected to the welding
power source.
4
6
Do not coil excess cables. Use cables
that are the appropriate length for the
application. Avoid coupling the volt
sense lead with the weld cables.
S
Use shortest cables possible for the job
S
Use proper sized work clamp and weld cables to accommodate peak amperages
S
Separate volt sense lead and feeder control cable from weld cables
S
Place weld cables together if possible
S
Connect work clamp as close to welding arc as possible
Bad
1
5
2
4
3
6
S
DO NOT coil cables
S
DO NOT share work clamps (no more than 1 machine per clamp)
S
DO NOT tangle cables from different machines
S
DO NOT splice weld cables
805 291-B
OM-236 891 Page 37
3-29. Typical Connection Diagram For Stick (SMAW) Equipment
1
2
3
4
5
6
1
Welding Power Source
Work (−) Weld Cable
Stick (+) Weld Cable
Workpiece
Electrode Holder
Volt Sense Lead
. Attach
volt sense lead to
work clamp and attach work
clamp as close to arc as possible.
3
6
2
5
4
805 294-A
OM-236 891 Page 38
3-30. Typical Connection Diagram For Two Piece Air-Cooled TIG (GTAW) Torch (Using
Gas Solenoid Inside Power Source)
1
2
3
4
5
6
7
8
1
Welding Power Source
Gas Hose
TIG (−) Weld Cable
Work (+) Weld Cable
Workpiece
TIG Torch
Volt Sense Lead
Remote Foot Control (Optional)
. Attach
volt sense lead to
work clamp and attach work
clamp as close to arc as possible.
2
3
4
7
6
5
8
805 295-A
OM-236 891 Page 39
3-31. Typical Connection Diagram For One Piece Air-Cooled TIG (GTAW) Torch (Using
Gas Solenoid Inside Power Source)
1
2
3
4
5
6
7
8
9
1
3
Welding Power Source
Gas Hose 237 415 (Short Black
Hose Supplied With Power
Source)
TIG Block (Customer Supplied)
TIG (−) Weld Cable
Work (+) Weld Cable
Workpiece
TIG Torch
Volt Sense Lead
Remote Foot Control (Optional)
. Attach
volt sense lead to
work clamp and attach work
clamp as close to arc as possible.
2
5
4
8
7
6
9
805 296-A
OM-236 891 Page 40
3-32. Typical Connection Diagram For Liquid-Cooled TIG (GTAW) Torch (Using Gas
Solenoid Inside Power Source)
1
2
3
4
Welding Power Source
Gas Hose
TIG Block (Customer Supplied)
Coolant Out Hose 237 416
(Short Red Hose Supplied With
Cooler)
5 TIG (−) Weld Cable
6 Coolant Return Hose
7 Work (+) Weld Cable
8 Workpiece
9 TIG Torch
10 Volt Sense Lead
11 Remote Foot Control (Optional)
1
3
. Attach
volt sense lead to
work clamp and attach work
clamp as close to arc as possible.
4
2
10
6
5
7
9
8
11
805 297-A
OM-236 891 Page 41
SECTION 4 − OPERATION
4-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
98/2 Ox
Gas mixture of 98% Argon and 2% O2.
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 RMD and Pulse processes. Increasing Arc
Control value increases the arc cone width and subsequently effects the arc length (end of electrode to
workpiece). See Section 4-7 items 1 and 4 for adjusting Arc Control value.
Arc Length
Distance from end of wire electrode to workpiece. This term is also used to represent arc length adjustments in
RMD and Pulse processes. Increasing Arc Length increases the actual arc length; likewise, decreasing Arc
Length shortens actual arc length. See Section 4-7 items 2 and 3 for adjusting arc length value.
Base Material
Selection of material to be welded (Carbon or Stainless Steel).
C2
Gas mixture of 98% Argon and 2% CO2.
C20-C25
Gas mixture of mainly Argon and 20-25% CO2.
C8-C15
Gas mixture of mainly Argon and 8-15% 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. See Section 4-2 item F 8 for setup procedure.
EXX10
Stick welding electrode type. EXXX1 or EXXX2 are typically used on this setting (cellulosic electrode).
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. Only dual shielded wire is recommended for the PipeWorx 400. A gas mixture or wire diameter
selection is not required. See wire manufacturer for the recommended gas mixture. The 0.035 to 0.062 wire
sizes can be used in the process.
Gas Type
Selection of shielding gas being used in an application: C8-C15 (Argon/8-15% CO2), C20-C25 (Argon/20-25%
CO2), C2 (Argon/2% CO2), 98/2 Ox (Argon/2% O2), TRI H (90% Helium/7.5% Argon/2.5% CO2), TRI A (81%
Argon/18% Helium/1% CO2).
HF
TIG starting method. High frequency turns on to help start the arc when output is enabled. High frequency turns
off when arc is started and turns on whenever the arc is broken to help restart the arc. HF start is used for
GTAW process when a non-contact arc start method is required.
Inductance Control
Allows setting inductance in MIG and FCAW. In short circuit GMAW welding, an increase in inductance will
decrease the number of short circuit transfers per second (provided no other changes are made) and increase
the arc-on time. The increased arc-on time makes the welding puddle more fluid. See Section 4-7 items 1 and 4
for adjusting Inductance Control value.
Jog
Method for feeding wire without contactor or gas valve being energized (see Section 4-7, item 9).
Lift-Arc
TIG starting method. Touch tungsten electrode to workpiece at weld start point and enable output and shielding
gas with torch trigger, foot control, or hand control (if a control is desired). Hold electrode to workpiece for one to
two seconds, and slowly lift electrode to form the arc. Lift-Arc is used for the GTAW process when HF Start
method is not permitted.
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.
Postflow
The time that the shielding gas continues to flow after the arc has been terminated.
Process
A selection made for MIG, Pulse, RMD, Stick, Flux Core (FCAW), or TIG (Lift-Arc or HF starts).
Memory Location Buttons
1-4
By selecting a process such as STICK, TIG, MIG LEFT side of feeder, or MIG right side of feeder there will be
four Memory Locations available for selection providing a total of 16 Memory Locations for a dual feeder. There
will only be 12 Memory Locations available for a single feeder.
Pulse
(Pro-Pulset)
An advanced pulse spray transfer process suited for the fill and cap passes on pipe. The Pulse process utilizes
constant current ramps with constant voltage control of peaks and backgrounds. Adaptive response is
controlled by peak and minimum current levels. Benefits are shorter arc lengths, better puddle control, more
tolerance of tip-to-work variation, less audible noise, no arc wandering, allows weld to fill in at toes increasing
travel speed and deposition, and more tolerant to poor fit up and gaps. Settings for Pulse include Arc Length,
Wire Speed and Arc Control.
Purge
Method for erergizing the gas valve(s) to purge gas lines before welding and to preset gas pressure at the
regulator (see Section 4-7, 11).
OM-236 891 Page 42
4-1 . Operational Terms (Continued)
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.
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 and Pulse processes.
TIG (GTAW)
TIG (GTAW) welding uses a non-consumable tungsten electrode and shielding gas to produce a strong, clean,
high quality weld.
TRI A
Gas mixture of 81% Argon, 18% Helium and 1% CO2.
Trigger Hold
This feature reduces weldor fatigue by allowing continuous welding without holding the trigger. See Section 4-7
item 10 to set up the Trigger Hold feature.
Trigger Select
This feature allows the operator to select MIG processes in Memory Locations 1-4 by pressing the gun trigger.
See Section 4-2 item F 6 to set up the Trigger Select feature.
TRI H
Gas mixture of 90% Helium, 7.5% Argon and 2.5% CO2.
Trim
See Arc Length description.
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 10 seconds hold value at end of weld.
Wire Diameter
Selection of wire diameter for MIG RMD and Pulse processes. The 0.035 or 0.045 wire size must be selected
for MIG RMD and Pulse processes. The 0.035 to 0.062 wire sizes can be used with FCAW, but a wire selection
is not required.
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-236 891 Page 43
4-2. Welding Power Source Controls
A. Front Panel Controls
1
2
13
3 4
14
. Only illuminated controls can be
changed or adjusted.
1
2
3
4
5
Memory Card Slot
Memory Card Busy Indicator
Memory Card Save Button
Memory Card Load Button
Memory Card Indicator
7 8
15
16
9
5
10
12
11
17
6
18
19
6
7
8
Memory Location Buttons 1-4
Stick Process Select Button
Stick Electrode Type Select Button
13 MIG Process Type Select Button
14 Base Material Select Button
15 Wire Diameter Select Button
9
10
11
12
Ammeter Display
Amperage Adjust Knob
TIG Process Select Button
TIG Starting Method Select Button
16
17
18
19
Gas Type Select Button
Gas Selection Table
Trigger Select Button
Side Select Button
The memory card slot uses an SD
memory card.
SD Logo is a trademark of the 3C.
OM-236 891 Page 44
B. Memory Function Controls
1.
Memory Card Slot
This is the memory card slot. A memory card can be inserted into the slot and used for storing and retrieving operator
settings, providing custom MIG type weld process data, and loading firmware 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.
2.
Memory Card Busy Indicator
The memory card busy LED illuminates during the following conditions: storage/retrieval of operator settings, usage of
custom MIG type weld process, and firmware upgrades.
3.
Memory Card Save Button
Press and release this button to save all stored operator settings in memory locations 1-4 as a setup configuration file
to 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 PIPEWORX.TXT is updated on the Memory Card. This file has a PipeWorx 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.
4.
Memory Card 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 operator settings on the card to memory locations 1-4. The busy LED will
illuminate to indicate the load operation is in progress.
5.
Memory CARD Indicator
The memory CARD text will illuminate when custom MIG or TIG type weld process data is currently being used from
the memory card.
C. Using Optional Memory Card
1.
2.
3.
Memory Card Insertion
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.
Memory Card Removal
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.
Optional Program Card Operation
a.
Insert optional program card into slot.
b.
Select wire feeder as follows:
Press either the LEFT or RIGHT (dual feeder only) button on the feeder.
or
Press the SIDE SELECT button on the power source until the desired wire feeder side is illuminated.
c.
Select weld process by pressing the MIG TYPE button on the power source front panel until the desired
process is illuminated.
CARD 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.
d.
Select the wire diameter, if applicable, as follows:
Press the WIRE DIA button on the power source front panel until the desired wire diameter is illuminated.
. Some optional program cards only support a single wire diameter, in this case, only that diameter will illuminate.
e.
Remove memory card to revert to standard operation.
OM-236 891 Page 45
4.
Software Update Card (System Software Update)
a.
Insert software update card into slot.
b.
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.
c.
Wait for the software update to complete (approximately two minutes).
. 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 software 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.
d.
Remove memory card.
D. Memory Locations
1.
Memory Location Buttons 1-4
These are locations for storing weld process settings for easy access. Press and release these buttons to recall stored
unit configuration settings. Only one memory location can be active during unit operation. The number next to the
button illuminates to indicate the active memory location. Unit configuration settings are automatically saved to the
active memory location one second after any change is made to any of the front panel controls. This feature allows the
unit to remember an operator’s preferred settings. These settings can be recalled at any time by selecting the appropriate memory location and process/feeder side. By selecting a process such as STICK, TIG, MIG LEFT side of
feeder, or MIG RIGHT side of feeder there will be four Memory Locations available for each, providing a total of 16
Memory Locations for a dual feeder. There will only be 12 Memory Locations available for a single feeder.
2.
Memory Location Reset
Pressing and holding a memory location button for more than two seconds will restore factory default settings for the
current weld process to that particular memory location. The memory location number light will go out and back on
when the reset is complete.
E. Stick And TIG Welding Process Controls
1.
Stick Process Select Button
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 adjust 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. If the Stick process has been selected, the optional Stick remote current/contactor control
is enabled (see Section 3-7), and a remote current/contactor control is connected, holding the Stick process select
button for more than two seconds will display the effective amperage command (based on the amperage setting and
the remote current/contactor control setting).
2.
Stick Electrode Type Select Button
Press and release this button to select the desired stick electrode type (EXX10 or 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.
3.
Ammeter Display
The display illuminates and shows amperage setting when either a stick or TIG welding process is selected. Dashes
are displayed when any MIG welding process is selected indicating the display is inactive; however, actual amperage
is displayed while welding regardless of the selected welding process. Measured amperage just prior to the end of a
welding operation will appear on the display for 10 seconds after the welding operation.
4.
Amperage Adjust Knob
Use this knob to set a desired amperage setting for either a stick or TIG 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 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.
. The Remote 14 receptacle is factory set to be active in TIG mode only. As an option, this receptacle may also be enabled in Stick mode (see
Section 3-7).
OM-236 891 Page 46
5.
TIG Process Select Button
Press and release this button to activate the TIG welding process controls. The TIG text below the button illuminates
as well as the active starting method text and the swoosh above the amperage adjust knob. The operator must select
the desired starting method and adjust the amperage knob to the appropriate setting within a range from 10 to 350
amps. If the TIG process has been selected and a remote current/contactor control is connected, holding the TIG
process select button for more than two seconds will display the effective amperage command (based on the amperage setting and the remote current/contactor control setting).
6.
TIG Starting Method Select Button
Press and release this button to select the desired TIG starting method either HF or Lift Arc. The text above or below
the button will illuminate for the active starting method. This button is only active with the TIG welding process selection and only then will text for the starting method selection illuminate.
F. MIG Welding Process Controls
. The reference to left side feeder controls or left side gun trigger applies to either a single feeder or dual feeder. The reference to right side
feeder controls or right side gun trigger only applies to a dual feeder.
The controls in the MIG setup panel are only active when in the MIG process. Press and release the SIDE SELECT
button to activate the MIG process and the desired feeder side. The LEFT or RIGHT text will illuminate to indicate
the the active feeder side (only LEFT will illuminate when using a single feeder). The MIG welding process controls can
also be activated at the feeder front panel by pressing LEFT or RIGHT, or by pressing the left or right side gun trigger
(see Section 4-7A). The MIG setup panel controls on the welding power source should be selected in order from left to
right starting with MIG type and ending with trigger select.
1.
MIG TYPE Process Select Button
Press and release the MIG TYPE button to select the desired process (FCAW, MIG, RMD, or PULSE). The text
illuminates to the right of this button to indicate the active process selection:
FCAW − gas shielded flux cored welding process
MIG (GMAW)− standard short circuit or spray welding process
RMDt (Regulated Metal Deposition) − modified short circuit welding process
PULSE (GMAW-P) − Pro-Pulset pulse welding process.
2.
BASE MATERIAL Select Button
Press and release BASE MATERIAL button to select the desired material (CARBON or STAINLESS steel). The text
illuminates above or below the button to indicate the active material selection. This selection is required for all MIG
process types except FCAW.
3.
WIRE DIAMETER Select Button
Press and release the WIRE DIA button to select the desired wire diameter (0.035 or 0.045). The text illuminates
above or below the button to indicate the active wire diameter selection. This selection is required for all MIG process
types except FCAW.
4.
GAS TYPE Select Button
Press and release GAS TYPE button to select the desired shielding gas. This button will cycle through and illuminate
only the available gas selections in one particular column of the gas table based on the selected MIG process and
BASE MATERIAL type. The text illuminates above the button when any MIG process is selected except FCAW.
OM-236 891 Page 47
5.
Gas Selection Table
The gas selection table provides the available shielding gas selections. For any MIG process except FCAW, gas
selections are structured into columns based first on BASE MATERIAL type and then on MIG process selections. The
gas type text illuminates to indicate the active gas selection. Shielding gas selections are as follows:
C8-C15 (92% Argon/8% CO2 to 85% Argon/15% CO2)
C20-C25 (80% Argon/20% CO2 to 75% Argon/25% CO2)
C2 (98% Argon/2% CO2)
98/2 Ox (98% Argon/2% O2)
TRI H (90% Helium/7.5% Argon/2.5% CO2)
TRI A (81% Argon/18% Helium/1% CO2)
6.
TRIGGER SELECT Button
Press and release TRIGGER SELECT button to enable/disable the trigger select feature for memory locations 1-4.
This feature must have at least two memory locations enabled to perform its function, but as many as four memory
locations can be enabled for TRIGGER SELECT. The desired MIG process type(s) and parameter settings should first
be loaded to each memory location prior to welding. These parameter settings (voltage/arc length and wire feed
speed) are made at the wire feeder front panel (see Section 4-7). Once parameters are set, quickly press and release
gun trigger, in less than 0.2 seconds while not welding, to select the next enabled memory location. If the gun trigger is
pressed and held for 0.2 seconds or longer, the memory location will not advance and parameter settings will remain at
the current settings.
7.
SIDE SELECT Button
Press and release SIDE SELECT button to select the MIG process and the desired side of a dual feeder (only LEFT
will illuminate when using a single feeder).
8.
Dual Schedule
To use Dual Schedule, plug in the switch, and select the MIG TYPE Process with the necessary selections and
parameters with the switch in one position. Then move the switch position and select the MIG TYPE Process with the
necessary selections and parameters again. Essentially, there are two programs saved to the selected memory
location.
OM-236 891 Page 48
4-3. Stick Process Selection Setup Example
2
1
. Only illuminated controls can
be changed or adjusted.
3
4
1
Stick Process Active
3
Amperage Setting 350A
2
EXX10 Electrode Type Selected
4
Memory Location 1 Active
OM-236 891 Page 49
4-4. TIG Process Selection Setup Example
3
. Only illuminated controls can
be changed or adjusted.
OM-236 891 Page 50
1
2
1
TIG Process Active
3
Amperage Setting 350A
2
HF Start Method Selected
4
Memory Location 2 Active
4
4-5. MIG Process Selection Setup Example 1
7
1
1
2
3
5
4
6
. Only illuminated controls can
be changed or adjusted.
2
Carbon Steel Base Material Selected
5
Trigger Select On
3
0.035 Wire Diameter Selected
6
Side Select Left
MIG Process Active
4
C8-C15 Gas Type Selected
7
Memory Location 3 Active
OM-236 891 Page 51
4-6. MIG Process Selection Setup Example 2
7
1
2
. Only illuminated controls can
be changed or adjusted.
1
Pro-Pulse MIG Process Active
OM-236 891 Page 52
5
4
3
2
3
4
Stainless Steel Base Material
Selected
0.035 Wire Diameter Selected
TRI-H Gas Type Selected
6
5
Trigger Select On
6
Side Select Left
7
Memory Location 4 Active
4-7. Wire Feeder Controls
A. Front Panel Controls
3
2
4
1
5
6
7
8
1
2
3
10
9
11
12
. Only illuminated controls can be
4
Right Side Controls Select Button*
9
changed or adjusted.
5
Wire Feed Speed Display
10 Trigger Hold Select Button
Left Side Controls Select Button
Volts/Arc Length Display
Volts/Arc Length Adjust Knob
6
7
Wire Feed Speed Adjust Knob
Memory Card Indicator
11 Purge Button
8
MIG Process Type Indicator
Jog Button
12 Memory Select Button And Location
Indicator
*Dual Feeder Only
OM-236 891 Page 53
1.
Left Side Controls Select Button
Press and release this button to activate the wire feeder left side controls. The LEFT text below the button will
illuminate and the swooshes above the volts/arc length adjustment knob and wire feed speed adjustment knob will
illuminate. See Section 4-2 for the procedure to select the appropriate MIG process type parameters. Pressing the left
side welding gun trigger will also active the left side controls.
When in Pulse or RMD, holding the Left Side Select button for more than two seconds will activate Arc Control. “ARC”
will be shown on the lower display and the Arc Control value on the upper display. The setable range is −25 to +25 with
0 as nominal. Increasing Arc Control value increases the arc cone width and subsequently effects the arc length (end
of electrode to workpiece distance). Decreasing Arc Control value decreases the arc cone width and subsequently
effects the arc length (electrode to workpiece distance).
When in MIG or FCAW, holding the Left Side Select button for more than two seconds will activate Inductance Control.
“IND” will be shown on the lower display and the Inductance Control value on the upper display. The setable range is 0
to 99 with nominal setting being program specific. An increase in inductance will decrease the number of short circuit
transfers per second (provided no other changes are made) and increase the arc-on time. The increased arc-on time
makes the welding puddle more fluid. A decrease in inductance will increase the number of short circuit transfers per
second (provided no other changes are made) and decrease the arc-on time. The decreased arc-on time makes the
welding puddle less fluid.
2.
Volts/Arc Length Display
This display shows the voltage setting for MIG and FCAW processes (10.0 to 44.0 volts), and it shows the arc length
for RMD and Pro-Pulse processes (−3.0 to +3.0 in 0.1 increments with 0 as nominal). The actual arc voltage is
displayed while welding and continues to appear for 10 seconds after the welding arc is extinguished. Dashes appear
on the display when other welding processes are selected.
3.
Volts/Arc Length Adjust Knob
Use this knob to adjust the desired voltage setting (10.0 to 44.0 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 selection. Rotating the knob clockwise increases
volts/arc length and counter-clockwise decreases volts/arc length. Volts/arc length adjustment is active when the
swoosh above the knob is illuminated. The setting can be different for left and right sides, and the unit will hold these
settings for both sides.
4.
Right Side Controls Select Button (Dual Feeder Only)
Press and release this button to activate the wire feeder right side controls. The RIGHT text below the button will
illuminate and the swooshes above the volts/arc length adjustment knob and wire feed speed adjustment knob will
illuminate. See Section 4-2 for the procedure to select the appropriate MIG process type parameters. Pressing the
right side welding gun trigger will also active the right side controls.
When in Pulse or RMD, holding the Right Side Select button for more than two seconds will activate Arc Control. “ARC”
will be shown on the lower display and the Arc Control value on the upper display. The setable range is −25 to +25 with
0 as nominal. Increasing Arc Control value increases the arc cone width and subsequently effects the arc length (end
of electrode to workpiece distance). Decreasing Arc Control value decreases the arc cone width and subsequently
effects the arc length (end of electrode to workpiece distance).
When in MIG or FCAW, holding the Left Side Select button for more than two seconds will activate Inductance Control.
“IND” will be shown on the lower display and the Inductance Control value on the upper display. The setable range is 0
to 99 with nominal setting being program specific. An increase in inductance will decrease the number of short circuit
transfers per second (provided no other changes are made) and increase the arc-on time. The increased arc-on time
makes the welding puddle more fluid. A decrease in inductance will increase the number of short circuit transfers per
second (provided no other changes are made) and decrease the arc-on time. The decreased arc-on time makes the
welding puddle less fluid.
5.
Wire Feed Speed Display
This display shows the wire feed speed setting when any of the MIG process types are selected and the display is
blank when other processes are selected. The wire feed speed range that can be displayed is from 50 to 780 ipm (1.3
to 19.8 mpm). Also, when the jog button is pressed the current jog speed appears on the display.
OM-236 891 Page 54
6.
Wire Feed Speed Adjust Knob
Use this knob to adjust the desired wire feed speed setting [50 to 780 ipm 1.3 to 19.8 mpm)]. Rotating the knob
clockwise increases wire feed speed and counter-clockwise decreases wire feed speed. Wire feed speed adjustment
is active when the swoosh above the knob is illuminated. The setting can be different for left and right sides and MIG
process type, and the unit will hold these settings for both sides.
7.
Memory Card Indicator
The CARD text will illuminate to indicate that custom MIG type weld process data is currently being used from the
memory card.
8.
MIG Process Type Indicator
The FCAW, MIG, RMD, or PULSE text illuminates to indicate which type of MIG process is selected at the welding
power source (see Section 4-2). No text illuminates when other welding processes are selected.
9.
Jog Button
Press and hold this button to jog wire on either the left or right side depending on the active side selection. Rotate the
wire feed speed adjustment knob to change jog speed. Rotating the knob clockwise increases jog speed and
counter-clockwise decreases jog speed. Release the button to stop the jog operation and the display will return to the
initial wire feed speed setting.
Wire jog is also initiated by pressing and holding the MIG gun trigger without establishing an arc. If the gun trigger is
depressed and an arc is not established, the feeder will automatically go into jog after 2 seconds.
Auto Jog
S
Pressing and releasing the jog and trigger hold buttons simultaneously will activate the auto jog function.
Depending on the active side selection, the left or right (dual feeder only) side will automatically jog a preset
amount of wire. The volts/arc length display will count down in 0.1 ft or 0.01 m decrements starting at the preset
wire length. A default preset wire length is set at 15.3 ft (4.7 m), but the length can be changed within a range of
5.0 to 30.0 ft (1.5 to 9.1 m) using the volts/arc length adjust knob. Rotating the knob clockwise increases wire
length and counter-clockwise decreases wire length. The volts/arc length 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 count down display. Jog speed can also be adjusted within a range of 50 to 780
ipm (1.3 to 19.8 mpm) using the wire feed speed adjust knob and the wire feed speed display will show the
current jog speed setting.
10.
Trigger Hold Select Button
Press and release this button to enable/disable the trigger hold feature. The text above or below the button, either ON
or OFF respectively, illuminates to indicate the current trigger hold selection. When trigger hold is active, the gun
trigger must be pressed and held for a minimum of one half second, but not more than six seconds. Then releasing the
gun trigger activates the trigger hold function. To stop welding, press and release the gun trigger.
11.
Purge Button
Press and hold this button to purge shielding gas lines prior to welding and to preset gas pressure at the regulator for
either the left or right (dual feeder only) side. This button will also purge the TIG gas solenoid located at the welding
power source if the TIG welding process is selected. Release the button to stop the purge operation.
Timed Purge
S
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.
12.
Memory Select Button And Location Indicator
Press and release this button to scroll through stored unit configuration in locations 1-4. This button can only recall
configurations and cannot be used to restore factory default settings to a memory location (see Section 4-2).The
numeral next to the button illuminates to indicate the active memory location.
OM-236 891 Page 55
4-8. Postflow Adjustment
Postflow times can be configured for each of the TIG, Wire Feeder Left and Wire Feeder Right outputs. These times
are global settings (i.e. all memory slots share the same three postflow settings; it is not possible to set different postflow times between memory slots).
The unit is shipped in the standard configuration (“Std” appears on the display). In the standard configuration postflow
times are automatically calculated as follows:
For TIG, the postflow time is a function of output current where the minimum time is 8 seconds from 0 to 175 amps and
increases linearly form 8 seconds at 175 amps to 16 seconds at 350 amps.
For wire processes, the postflow time is a function of wire feed speed where the minimum time is 8 seconds from 0 to
390 ipm and increases linearly for 8 seconds at 390 ipm to 16 seconds at 780 ipm.
To adjust postflow time, proceed as follows:
1.
Select desired output: TIG, LEFT or RIGHT.
2.
Press and hold the Purge button, gas solenoid will open.
3.
Rotate the Wire Feed Speed knob, gas solenoid will close.
Unit will display PSt on the Voltage display and postflow setting on the Wire Feed Speed display (Std appears if
this is the first time).
4.
Release the Purge button.
5.
Adjust postflow time to desired value by rotate the Wire Feed Speed knob.
Available selections include Std and numeric values from 0 to 60 seconds.
6.
Press any button to return to the normal display.
OM-236 891 Page 56
4-9. Wire Feeder Left Side Active Setup Example
1
4
2
3
. Only illuminated controls can be
changed or adjusted.
1
Left Side Controls Active
3
Trigger Hold Off
2
MIG Process Selected
4
Memory Location 1 Active
OM-236 891 Page 57
4-10. Wire Feeder Right Side Active Setup Example (Dual Feeder Only)
1
4
2
3
. Only illuminated controls can be
changed or adjusted.
OM-236 891 Page 58
1
Right Side Controls Active
3
Trigger Hold On
2
Pulse Process Selected
4
Memory Location 2 Active
4-11. Wire Feeder Non-MIG Setup Example
2
1
. Only illuminated controls can be
1
Non-MIG Process Selected
2
Memory Location 3 Active
changed or adjusted.
OM-236 891 Page 59
4-12. Wire Feeder Timed Purge Example
2
3
1
. Only illuminated controls can be
1
changed or adjusted.
Purge And Trigger Hold Buttons
OM-236 891 Page 60
2
Pressed Simultaneously
Purge Time Setting Adjustment Knob
3
Purge Time Remaining Display
4-13. Wire Feeder Auto Jog Example
2
3
5
4
1
. Only illuminated controls can be
1
changed or adjusted.
Jog And Trigger Hold Buttons Pressed
2
3
Simultaneously
Jog Feet Adjustment Knob
Jog Feet Remaining Display
4
5
Jog Wire Feed Speed Adjustment Knob
Jog Wire Feed Speed Display
OM-236 891 Page 61
4-14. Basic Parameters For PipeWorx 400
Steel
Process
Wire Size
in. (mm)
Wire Feed Speed
IPM (mpm)
Arc Length
Shielding Gas
.035 (0.9)
100-350 w/200 Nominal
(2.5-8.9 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
C8 − C15
.035 (0.9)
100-350 w/200 Nominal
(2.5-8.9 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
C20 − C25
.035 (0.9)
100-250 w/200 Nominal
(2.5-6.4 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
CO2
.045 (1.1)
100-250 w/150 Nominal
(2.5-6.4 w/3.8 Nominal)
+3.0 to −3.0
w/zero Nominal
C8 − C15
.045 (1.1)
100-250 w/150 Nominal
(2.5-6.4 w/3.8 Nominal)
+3.0 to −3.0
w/zero Nominal
C20 − C25
.045 (1.1)
100-200 w/150 Nominal
(2.5-5.1 w/3.8 Nominal)
+3.0 to −3.0
w/zero Nominal
CO2
.035 (0.9)
120-780 w/250 Nominal
(3.0-19.8 w/6.4 Nominal)
+3.0 to −3.0
w/zero Nominal
C8 − C15
.045 (1.1)
140-500 w/250 Nominal
(3.6-12.7 w/6.4 Nominal)
+3.0 to −3.0
w/zero Nominal
C8 − C15
.035 (0.9)
120-780 w/200 Nominal
(3.0-19.8 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
C8 − C15
.045 (1.1)
140-500 w/175 Nominal
(3.6-12.7 w/4.4 Nominal)
+3.0 to −3.0
w/zero Nominal
C8 − C15
RMD Steel
ProPulse Steel Using A
Positioner
(Rolling The Pipe)
ProPulse Steel
Welding In Position
OM-236 891 Page 62
Stainless Steel
Process
Wire Size
in. (mm)
Wire Feed Speed
IPM (mpm)
Arc Length
Shielding Gas
.035 (0.9)
120-350 w/200 Nominal
(3.0-8.9 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
C2
.035 (0.9)
120-350 w/200 Nominal
(3.0-8.9 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
98/2 Ox
.035 (0.9)
120-350 w/200 Nominal
(3.0-8.9 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-H
.035 (0.9)
120-350 w/200 Nominal
(3.0-8.9 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-A
.045 (1.1)
120-250 w/150 Nominal
(3.0-6.4 w/3.8 Nominal)
+3.0 to −3.0
w/zero Nominal
C2
.045 (1.1)
120-250 w/150 Nominal
(3.0-6.4 w/3.8 Nominal)
+3.0 to −3.0
w/zero Nominal
98/2 Ox
.045 (1.1)
120-250 w/150 Nominal
(3.0-6.4 w/3.8 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-H
.045 (1.1)
120-250 w/150 Nominal
(3.0-6.4 w/3.8 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-A
RMD Stainless Steel
OM-236 891 Page 63
Stainless Steel
Process
ProPulse
Stainless Steel Using A
Positioner
(Rolling The Pipe)
ProPulse
Stainless Steel
Welding In Position
OM-236 891 Page 64
Wire Size
in. (mm)
Wire Feed Speed
IPM (mpm)
Arc Length
Shielding Gas
.035 (0.9)
150-780 w/250 Nominal
(3.8-19.8 w/6.4 Nominal)
+3.0 to −3.0
w/zero Nominal
C2
.035 (0.9)
150-780 w/250 Nominal
(3.8-19.8 w/6.4 Nominal)
+3.0 to −3.0
w/zero Nominal
98/2 Ox
.035 (0.9)
225-600 w/250 Nominal
(5.7-15.2 w/6.4 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-H
.035 (0.9)
150-780 w/250 Nominal
(3.8-19.8 w/6.4 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-A
.045 (1.1)
120-780 w/200 Nominal
(3.0-19.8 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
C2
.045 (1.1)
120-780 w/200 Nominal
(3.0-19.8 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
98/2 Ox
.045 (1.1)
140-780 w/200 Nominal
(3.6-19.8 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-H
.045 (1.1)
120-780 w/200 Nominal
(3.0-19.8 w/5.1 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-A
.035 (0.9)
150-780 w/175 Nominal
(3.8-19.8 w/4.4 Nominal)
+3.0 to −3.0
w/zero Nominal
C2
.035 (0.9)
150-780 w/175 Nominal
(3.8-19.8 w/4.4 Nominal)
+3.0 to −3.0
w/zero Nominal
98/2 Ox
.035 (0.9)
150-780 w/175 Nominal
(3.8-19.8 w/4.4 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-H
.035 (0.9)
150-780 w/175 Nominal
(3.8-19.8 w/4.4 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-A
.045 (1.1)
120-525 w/140 Nominal
(3.0-13.3 w/3.6 Nominal)
+3.0 to −3.0
w/zero Nominal
C2
.045 (1.1)
120-525 w/140 Nominal
(3.0-13.3 w/3.6 Nominal)
+3.0 to −3.0
w/zero Nominal
98/2 Ox
.045 (1.1)
120-525 w/140 Nominal
(3.0-13.3 w/3.6 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-H
.045 (1.1)
120-525 w/140 Nominal
(3.0-13.3 w/3.6 Nominal)
+3.0 to −3.0
w/zero Nominal
Tri-A
Flux Core
Process
Wire Size
in. (mm)
Rolling Pipe/In Position
Wire Feed Speed
IPM (mpm)
Voltage
Shielding Gas
Flux Core/GMAW
Not
Dependent
175-780 w/200 Nominal
(4.4-19.8 w/5.1 Nominal)*
24.5-32 w/24.5 Nominal
Not Dependent
Note: Arc Length − Length of arc from end of wire to weld puddle. Wire feed speed and voltage are synergic for the
RMD and ProPulse processes. This means when adjusting wire feed speed, the voltage is automatically adjusted so
it is not necessary to adjust the Arc Length.
*See wire manufacturer for recommended wire feed speed and gas mixture.
4-15. Lift-Arc™ And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to
workpiece at weld start point,
enable output and shielding gas
with torch trigger, foot control, or
hand control (if a remote control is
connected). Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN or
process when HF Start method is
not permitted, or to replace the
scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to help
start arc when output is enabled.
High frequency turns off when arc is
started, and turns on whenever arc
is broken to help restart arc.
Application:
HF start is used for the DCEN
GTAW process when a non-contact arc starting method is required.
OM-236 891 Page 65
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. 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
l Cracked Torch Body
Every
6
Months
l Cracked Parts
Or
~ Inside Unit
~ Drive Rolls
5-2. 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. 805 142-A
OM-236 891 Page 66
5-3. Restoring Factory Defaults
Full System
A full factory reset can be accomplished by pressing memory location buttons 1 and 4 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.
Memory Location
See Section 4-2 D2 the reset procedure.
5-4. Viewing Software Revision
Pressing the MIG TYPE and SIDE SELECT buttons behind the door on the power source simultaneously will display
the Software Revision.
5-5. Power Source Calibration Procedure
Only qualified persons should install, operate, maintain, and repair this unit.
A. Required Equipment
1.
Calibrated DC voltmeter and clamp-on DC ammeter (e.g. Fluke 337)
2.
Calibration Card
3.
Shorting cable (2/0)
B. Calibration Procedure
1.
Disconnect cables from all output studs.
2.
Turn on power to the welding system.
3.
Insert Calibration card.
4.
5.
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 MIG voltage as follows:
a.
Connect voltmeter from MIG stud (on rear of unit) to Work stud (front center).
b.
Press memory 1 button on the power source front panel. Open circuit voltage should now be present
from MIG output stud to the Work stud.
c.
Using the knob on the power source front panel, set the display voltage to the measured value on
the voltmeter.
d.
Press memory 1 button on the power source front panel to end the MIG voltage calibration.
e.
Power source will display CAL.
Calibrate TIG voltage as follows:
a.
Connect voltmeter from Work stud (front center) to TIG stud (front right).
b.
Press memory 2 button on the power source front panel. Open circuit voltage should now be present
from TIG output stud to the Work stud.
c.
Using the knob on the power source front panel, set the display voltage to the measured value on
the voltmeter.
d.
Press memory 2 button on the power source front panel to end the TIG voltage calibration.
e.
Power source will display CAL.
OM-236 891 Page 67
6.
7.
8.
9.
Calibrate STICK voltage as follows:
a.
Connect voltmeter from STICK stud (front left) to Work stud (front center).
b.
Press memory 3 button on the power source front panel. Open circuit voltage should now be present
from STICK output stud to the Work stud.
c.
Using the knob on the power source front panel, set the display voltage to the measured value on
the voltmeter.
d.
Press memory 3 button on the power source front panel to end the STICK voltage calibration.
e.
Power source will display CAL.
Calibrate amperage as follows:
a.
Connect shorting cable from STICK stud (front left) to Work stud (front center).
b.
Attach clamp-on ammeter around shorting cable.
c.
Press memory 4 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 memory 4 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-236 891 Page 68
5-6. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460 Volt
Models
!
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
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.
Proceed with job inside unit. Reinstall
right side panel when finished.
1
2
3
230 VAC input:
+ lead to lower
terminal, − lead to
upper terminal
2
3
460 VAC input:
+ lead to lower right
terminal, − lead to
upper left terminal
Tools Needed:
5/16 in.
Ref. 805 142-A / Ref. 805 145-A
OM-236 891 Page 69
5-7. Removing Right Side Panel and Measuring Input Capacitor Voltage In
575 Volt Models
!
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
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.
Proceed with job inside unit. Reinstall
right side panel when finished.
1
2
3
+ lead to lower right
terminal, − lead to
upper right terminal
Tools Needed:
5/16 in.
Ref. 805 142-A / Ref. 805 145-A
OM-236 891 Page 70
5-8. Cooler Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
~Clean coolant strainer. Severe
conditions may require more frequent
cleaning (continuous use, high/low
temperatures, dirty environment,
etc.). Failure to properly clean coolant
strainer voids pump warranty.
Δ = Repair
Disconnect cooler plug from welding
power source receptacle before
maintaining.
l = Replace
~ Blow out heat exchanger fins.
nCheck coolant level.
Every
6
Months
nlHoses
nl Labels
Every
12
Months
ZChange coolant (if using Miller coolant).
OM-236 891 Page 71
5-9. Coolant Maintenance
!
Disconnect cooler plug from
welding power source receptacle before maintaining.
1
2
Cooler Housing
Cooler Drawer
Remove 4 screws from front of
cooler housing and slide cooler
drawer out.
3
Coolant Filter
Unscrew housing to clean filter and
housing.
Changing coolant: Drain coolant by
tipping unit forward. Fill with clean
water and run for 10 minutes. Drain
and refill.
. If
replacing hoses, use
hoses
compatible
with
ethylene glycol, such as
Buna-n,
Neoprene,
or
Hypalon.
NOTE: Oxy-acetylene hoses
are not compatible with any
product containing ethylene
glycol.
1
2
Reinstall cooler drawer into housing.
3
801 195-A / Ref. 801 194
OM-236 891 Page 72
5-10. 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
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.
H04
Secondary Circuit Over Temperature
Indicates bottom of unit has overheated. Unit has shutdown to
allow fans to lower bottom temperature. Operation will continue
after unit is within normal temperature range.
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.
Check for correct voltage linking (see Section 3-14).
H25
Duty Cycle
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.
H26
Button Stuck Power Source
H30
Stuck Contactor TIG
Indicates stuck remote contactor in TIG mode. Fault will clear
when foot pedal or control device contactor is released.
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 Left
Indicates tach error on left motor. Check left feeder drive housing
and wire spool for obstructions. If this code continues to appear on
the display, contact the nearest Factory Authorized Service Agent.
H41
Tach Right
Indicates tach error on right motor. Check right 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 Left
Indicates motor error on left motor. Check left feeder drive
housing and wire spool for obstructions. If this code continues
to appear on the display, contact the nearest Factory Authorized Service Agent.
Indicates thermal protection circuitry is malfunctioning. If this
code appears on the display, contact the nearest Factory
Authorized Service Agent.
Indicates button is stuck on the power source upon start up.
Fault will clear when button is released.
OM-236 891 Page 73
H43
Motor Right
Indicates motor error on right motor. Check right 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.
Check for correct voltage linking (see Section 3-14).
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.
H46
Trigger Stuck Left
H47
Trigger Stuck Right
H48
Trigger Fault Left
H49
Trigger Fault Right
Indicates right 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.
H70
Weld Library
H98
Serial Communication Loss
H99
Serial Communication Malfunction
OM-236 891 Page 74
Indicates left trigger stuck fault. Fault will clear when left trigger
is released.
Indicates right trigger stuck fault. Fault will clear when right
trigger is released.
Indicates left trigger was held too long in trigger jog (the lesser
of 60 seconds or 30 ft (9.1 m) of wire.
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.
5-11. 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.
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 volt sensing lead is connected to the welding power source and that work connection is secure. Check
for any frayed wires at work end of volt sensing lead that may prevent a good connection.
S
Be sure that volt 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.
S
Refer to Pipe Welding Techniques DVD.
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-236 891 Page 75
5-12. Welding Power Source Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-15).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-15).
Check for proper input power connections (see Section 3-15).
No weld output; meter display On.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-3).
Check voltmeter/ammeter Help displays.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-18).
Clean and tighten all weld connections.
Check volt sense lead. Straighten any coiled cables.
No 115 volts AC output at single
receptacle.
Reset supplementary protector CB1 (see Section 3-11).
No 24 volts AC output at Remote 14
Feeder receptacle.
Reset supplementary protector CB2 (see Section 3-10).
When remote control is connected to Check remote control switch and potentiometer resistances.
unit output is always on.
OM-236 891 Page 76
5-13. 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 (see Section 3-26).
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-236 891 Page 77
5-14. Cooler Troubleshooting
!
Disconnect power before troubleshooting.
Trouble
Coolant system does not work.
Remedy
Be sure input power cord is plugged into energized receptacle.
Check supplementary protector CB1 at welding power source, and reset if necessary.
Motor overheated. Unit starts running when motor has cooled.
Have Factory Authorized Service Agent check motor.
Decreased or no coolant flow.
Add coolant.
Check for clogged hoses or coolant filter.
Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
OM-236 891 Page 78
Notes
OM-236 891 Page 79
SECTION 6 − ELECTRICAL DIAGRAM
Figure 6-1. Circuit Diagram For Welding Power Source
OM-236 891 Page 80
234 105-F
OM-236 891 Page 81
Figure 6-2. Circuit Diagram For Single Or Dual Wire Feeder
OM-236 891 Page 82
236 220-E
OM-236 891 Page 83
238 662-A
Figure 6-2. Circuit Diagram For Cooler
OM-236 891 Page 84
Notes
OM-236 891 Page 85
SECTION 7 − PARTS LIST
. Hardware is
common and
not available unless listed.
8
6
7
80
1
16
15
12
2
3
92
10
4
91
5
11
13
14
21
9
31
22
23
20
17
18 19
90
93
24
78
25
79
30
88
32 29
43
89 87
27
33
76 75
74
73
77
86
85
26
35
95
72
34
28
39
36
37
38
40
84
71
83
70
82
67
69
41
94
37
43
68
45
46
66
42
44
47
48
61
50
60
62
63
49
65
51
59
64
52
58
80
57
53
81
56
55
54
Figure 7-1. Main Assembly
OM-236 891 Page 86
805 149-A
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
907 382 907 384
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . . . . +233480 . . PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 2 . . . CB2 . . . . . . 093995 . . SUPPLEMENTARY PRO,MAN RESET 1P 15A 250VAC FRICT 1 . . . .
. . . 3 . . PC11 . . . . . 233919 . . CIRCUIT CARD ASSY,PS/FEEDER INTERFACE . . . . . . . . . . . . 1 . . . .
. . . 4 . . . . . . . . . . . . . . 228036 . . VALVE, 24VAC 1WAY .750−14 THD 2.0MM ORF 100 PSI . . . . . 1 . . . .
. . . 5 . . . . . . . . . . . . . . 236638 . . HOSE,NPRN BRD NO 1 X .187 ID X 40.000 . . . . . . . . . . . . . . . . . 1 . . . .
. . . 6 . . . . . . . . . . . . . . 220805 . . NUT, 750−14 NPS 1.48HEX .41H NYL . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 7 . . . . . . . . . . . . . . 010467 . . CONN,CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 8 . . . . . . . . . . . . . . 181181 . . LABEL,WARNING MATCH INPUT POWER TO VOLTAGE . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 237163 . . LABEL,MIG OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 237157 . . LABEL,CB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 238560 . . LABEL,TIG GAS IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 237158 . . LABEL,TO WIREFEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 9 . C3, C4,
C5, C6 . . . . 192935 . . CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA . . . . . . . 4
. . . 9 . C3, C4,
C5, C6 . . . . 193738 . . CAPACITOR,ELCTLT 1800 UF 500 VDC CAN 2.52 DIA . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 218004 . . LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS . . 3 . . . .
. . . . . . . . . . . . . . . . . . . . 217040 . . NUT,NYLON M12 THREAD CAPACITOR MOUNTING . . . . . . . . 4 . . . .
. . . 10 . . . PC4 . . . . . . 184180 . . CIRCUIT CARD ASSY,INTERCONNECTING . . . . . . . . . . . . . . . . 1
. . . 10 . . . PC4 . . . . . . 186873 . . CIRCUIT CARD ASSY,INTERCONNECTING . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . 185214 . . BUS BAR,INTERCONNECTING 575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . PC10 . . . . . 234712 . . CIRCUIT CARD ASSY,RELINK 230/460 . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . +233486 . . PANEL,SIDE RH 230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . +240841 . . PANEL,SIDE RH 575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 237155 . . LABEL,IMPORTANT INPUT POWER/RELINK CONNECTIONS 1
. . . 15 . . . . . . . . . . . . . . 222317 . . LABEL,WARNING MATCH INPUT POWER . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 234271 . . SHEET,INSULATOR SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 17 FM1, FM2 . . . 222728 . . FAN,MUFFIN 24VDC 3000 RPM 255 CFM . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 18 . . . . . . . . . . . . . . 233501 . . BRACKET,FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 19 . . . L1 . . . . . . 180026 . . INDUCTOR,INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDTUNNEL,RH W/CMPNTS (INCLUDES) . . . . . . . . . . . . . . . . 1 . . . .
. . . 20 . . . . . . . . . . . . . . 030170 . . . . BUSHING,SNAP−IN NYL .750 ID X 1.000 MTG HOLE . . . . . . 2 . . . .
. . . 21 . . . . . . . . . . . . . . 025248 . . . . STAND−OFF,INSUL .250−20 X 1.250 LG X .437 THD . . . . . . . 4 . . . .
. . . 22 . . . W1 . . . . . . 180270 . . . . CONTACTOR,DEF PRP 40A 3P 24VAC COIL W/BOXLUG . . 1 . . . .
. . . 23 . . . CT1 . . . . . . 233620 . . . . XFMR,CURRENT 500 TURN POLARIZED . . . . . . . . . . . . . . . . 1 . . . .
. . . 24 . . . . . . . . . . . . . . 177547 . . . . BUSHING,SNAP−IN NYL CT−MOUNT 1.125 MTG HOLE . . . 1 . . . .
. . . 25 . . . . . . . . . . . . . . 010493 . . . . BUSHING,SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . 4 . . . .
. . . 26 . . . . . . . . . . . . . . 233462 . . . . WINDTUNNEL,RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 27 PM1, PM2 . . . 240144 . . . . KIT,TRANSISTOR IGBT MODULE . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 28 . . . . . . . . . . . . . . 179930 . . . . HEAT SINK,POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 29 . . . RT1 . . . . . . 173632 . . . . THERMISTOR,NTC 30K OHM @ 25 DEG C 12.00IN LEAD . . 1 . . . .
. . . 30 . . . SR1 . . . . . . 183334 . . . . RECTIFIER,INTEG BRIDGE 130. AMP 1600V 3PH . . . . . . . . . 1 . . . .
. . . 31 . . C1, C2 . . . . 230272 . . CAPACITOR,POLYP FILM .34 UF 1000 VRMS +/−10% . . . . . . . 2
. . . 30 . . C1, C2 . . . . 230270 . . CAPACITOR,POLYP FILM .22 UF 1000 VRMS +/−10% . . . . . . . . . . . . . .
. . . 32 . . . L2 . . . . . . 233438 . . INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 33 . . L3, L4 . . . . . 233617 . . INDUCTOR,DI−DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 34 . . . . . . . . . . . . . . 218566 . . GASKET,INDUCTOR MOUNTING E70 FERRITE CORE . . . . . . 2 . . . .
. . . 35 . . . CB1 . . . . . . 083432 . . SUPPLEMENTARY PRO,MAN RESET 1P 10A 250VAC FRICT 1 . . . .
. . . 36 . . . RC2 . . . . . . 134837 . . RCPT,STR GRD 2P3W 15A 125V SINGLE *5−15R . . . . . . . . . . . 1 . . . .
. . . 37 . . . . . . . . . . . . . . 170647 . . BUSHING,SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . 2 . . . .
. . . 38 . . . HD1 . . . . . . 168829 . . TRANSDUCER,CURRENT 1000A MODULE . . . . . . . . . . . . . . . . . 1 . . . .
. . . 39 . . . . . . . . . . . . . . 234358 . . BASE, W/ PEM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 40 . . . . . . . . . . . . . . 229325 . . FOOT,MTG UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . .
1
1
1
1
1
1
1
1
1
1
1
1
4
3
4
1
1
1
1
2
1
1
1
2
4
1
1
1
4
1
1
1
1
1
2
1
2
2
1
1
2
1
1
4
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 891 Page 87
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
907 382 907 384
Figure 7-1. Main Assembly
. . . 41 . . . . . . . . . . . . . . 210866 . . TERMINAL,PWR OUTPUT BLACK . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 42 . . . PC6 . . . . . . 237704 . . CIRCUIT CARD ASSY,REMOTE INTERFACE . . . . . . . . . . . . . . . 1 . . . .
. . . 43 . . . . . . . . . . . . . . 182665 . . TERMINAL,PWR OUTPUT NEUTRAL . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 44 . . . . . . . . . . . . . . 210865 . . TERMINAL,PWR OUTPUT RED . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 45 . . . . . . . . . . . . . . 236968 . . OVERLAY,SECONDARY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 46 . . . . . . . . . . . . . . 231191 . . SWITCH,TGL 3PST 50A 600VAC SCR TERM WIDE TGL . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 176226 . . INSULATOR,SWITCH POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 47 . . . . . . . . . . . . . . 120854 . . . . FTG,GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 48 . . . . . . . . . . . . . . 237415 . . HOSE,GAS BRAIDED 5 IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 49 . . . . . . . . . . . . . 236596 . . PLATE,SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 50 . . . . . . . . . . . . . . 241087 . . COVER,OUTPUT STUD W/LABELS (INCLUDES) . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 238574 . . . . LABEL,CONNECTION SECONDARY PANEL . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 238535 . . . . LABEL,PIPEWORX 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 51 . . . PC3 . . . . . . 233887 . . CIRCUIT CARD ASSY,UI W/PROGRAM PS . . . . . . . . . . . . . . . . . 1 . . . .
. . . 52 . . . . . . . . . . . . . . 234496 . . OVERLAY,POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 53 . . . . . . . . . . . . . . 174991 . . KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . 1 . . . .
. . . 54 . . . . . . . . . . . . . . 236828 . . DOOR,BEZEL,MIG SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 55 . . . . . . . . . . . . . . 234497 . . BEZEL,POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 56 . . . . . . . . . . . . . . 236830 . . DOOR,SD READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 57 . . . . . . . . . . . . . . 234344 . . BRACKET,SD CARD READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 58 . . PC12 . . . . . 236041 . . CIRCUIT CARD ASSY,SD CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 59 . . . . . . . . . . . . . . 236748 . . WHITEBOARD,MAGNETIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 60 . . . . . . . . . . . . . . 233479 . . PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 212810 . . LABEL,ON−OFF W/SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDTUNNEL,LH W/CMPNTS (INCLUDES) . . . . . . . . . . . . . . . . 1 . . . .
. . . 61 . . . . . . . . . . . . . . 233910 . . . . HEAT SINK,POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 62 . D1, D2,
D3, D4 . . . . 235029 . . . . DIODE,ULTRA−FAST RECOVERY 300A 600V DUAL . . . . . . . 4 . . . .
. . . 63 . . . . . . . . . . . . . . 233490 . . . . BUS BAR,DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 64 . . . . . . . . . . . . . . 233461 . . . . WINDTUNNEL,LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 65 . . . . . . . . . . . . . . 057358 . . . . BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE . . . . . 2 . . . .
. . . 66 . . . RT2 . . . . . . 222327 . . . . THERMISTOR,NTC 30K OHM @ 25 DEG C 24.00IN LEAD 1 . . . .
. . . 67 . . . . . . . . . . . . . . 232296 . . . . RESISTOR/CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 68 . . . . . . . . . . . . . . 233911 . . WINDTUNNEL BOTTOM, W/ PEM NUTS . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 69 . . . . T1 . . . . . . 233413 . . XFMR,HF 230/460 UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . T1 . . . . . . 236304 . . XFMR,HF 575 UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 70 . . SCR1,
SCR2, SCR3 . . 234711 . . THYRISTOR,SCR MODULE 500A 800V SINGLE . . . . . . . . . . . . 3 . . . .
. . . . . . . RT3,RT4 . . . . 234339 . . THERMISTOR,NTC 30K OHM @ 25 DEG C 12.00IN LEAD 2 . . . .
. . . 71 . . . . . . . . . . . . . . 234056 . . HEAT SINK,SCR POLARITY SWITCHING . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 72 . . . . . . . . . . . . . . 234279 . . BUS BAR,SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 73 . . . . T3 . . . . . . 233909 . . XFMR,HF ARC START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 74 . . . . . . . . . . . . . . 179848 . . BOOT,POSITIVE OUTPUT STUD . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 75 . . . . . . . . . . . . . . 180735 . . WASHER,OUTPUT STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDTUNNEL,TOP ASSY (INCLUDES) . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 76 . . . . . . . . . . . . . . 234280 . . . . BAFFLE,WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 77 . . . . . . . . . . . . . . 233476 . . . . WINDTUNNEL,TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 78 . . . . . . . . . . . . . . 233489 . . . . BRACKET,CAPACITOR SUPPORT . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 79 . . . . . . . . . . . . . . 216366 . . . . BUSHING,SNAP−IN NYL .500 ID X .625 MTG HOLE . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 170647 . . . . BUSHING,SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . 2 . . . .
. . . . . . . . . . . . . . . . . . . . 057358 . . . . BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 216596 . . . . STRAP,GROUNDING 4.50 IN LONG . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 80 . . . . . . . . . . . . . . 233485 . . PANEL,SIDE LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 81 . . . . . . . . . . . . . . 134327 . . LABEL,WARNING GENERAL PRECAUTIONARY STATIC . . . . 2 . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
OM-236 891 Page 88
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1
2
1
2
1
1
3
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
907 382 907 384
Figure 7-1. Main Assembly
. . . 82 . . . . . . . . . . . . . .
. . . 83 . . . . . . . . . . . . . .
. . . 84 . . . . . . . . . . . . . .
....................
....................
. . . 85 . . . PC9 . . . . . .
. . . 86 . . . . . . . . . . . . . .
. . . 87 . . . PC1 . . . . . .
. . . 88 . . . PC2 . . . . . .
. . . 88 . . . PC2 . . . . . .
....................
. . . 89 . . . . . . . . . . . . . .
....................
. . . 90 . . . . . . . . . . . . . .
. . . 91 . . . . . . . . . . . . . .
. . . 92 . . . PC5 . . . . . .
. . . 93 . . . . T2 . . . . . .
. . . 92 . . . . T2 . . . . . .
. . . 94 . . . . . . . . . . . . . .
. . . 95 . . . . . . . . . . . . . .
233483
233488
026627
236749
236778
233732
233892
233468
233463
236631
198122
236299
236770
233478
198122
236096
236645
236646
057358
219076
. . COVER,TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . FRAME,LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . GASKET,LIFTING EYE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . BRACKET,MTG CIRCUIT CARDS ASSY (INCLUDES) . . . . . . . . 1 . . . . .
. . BRACKET,MTG CIRCUIT CARDS ASSY (INCLUDES) . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD ASSY,SECONDARY GATE DRIVER . . . . . . . 1 . . . . 1
. . . . BRACKET,MTG CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . CIRCUIT CARD ASSY,PROCESS CONTROL W/PROGRAM 1 . . . . 1
. . . . CIRCUIT CARD ASSY,INVERTER CONTROL W/PROGRAM 1 . . . . .
. . . . CIRCUIT CARD ASSY,INVERTER CONTROL W/PROGRAM . . . . . . . 1
. . . . STAND−OFF SUPPORT,PC CARD .250W/POST&LOCK . . . . 10 . . . . 10
. . CHOKE,COMMON MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . BRACKET,MTG XFMR ASSY (INCLUDES) . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . BRACKET,MTG XFMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . STAND−OFF SUPPORT,PC CARD .250W/POST&LOCK . . . . 4 . . . . 4
. . . . CIRCUIT CARD ASSY,HF ARC STARTER . . . . . . . . . . . . . . . . . 1 . . . . 1
. . XFMR,CONTROL 230/460 VAC PRI 1589VA 60 HZ . . . . . . . . . . 1
. . XFMR,CONTROL 575 VAC PRI 1589VA 60 HZ . . . . . . . . . . . . . . . . . . . . . 1
. . BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE . . . . . . . 1 . . . . 1
. . CORE,FERRITE 22MM OD X 10MM ID X 33MM LG . . . . . . . 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-236 891 Page 89
. Hardware is
common and
not available unless listed.
1
5
4
2
7
6
8
24
3
25
10
9
27
26
11
21
23
17
19
20
22
12
13
18
14
16
15
805 300-A
Figure 7-2. Cooler
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Cooler
. . . 1 . . . . . . . . . . 173263
. . . 2 . . . . . . . . . . 134795
. . . 3 . . . . . . . . . . 173999
. . . 4 . . . . . . . . . . 094263
. . . . . . . . . . . . . . . . 236814
. . . 5 . . . . . . . . . . . . . 5523
. . . 6 . . . . . . . . . . 232424
. . . 7 . . . . . . . . . . 213072
. . . 8 . . . . . . . . . . 231341
. . . 9 . . . . . . . . . . 236813
. . . 10 . . . . . . . . . . 236845
. . . 11 . . . . . . . . . . 236846
. . . 12 . . . . . . . . . +236844
. . . 13 . . . . . . . . . . 203990
. . . 14 . . . . . . . . . . 229325
. . MOTOR,1/4HP 115VAC 50/60HZ 1425/1725 RPM DUAL . . . . . . . . . . . . . . . .
. . COUPLER,DRIVE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PUMP,COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP,1−EAR TYPE NOM DIM .718 X .276 WIDE . . . . . . . . . . . . . . . . . . . . .
. . ASSY,FAN/RADIATOR (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RADIATOR,HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLENUM,AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN,MUFFIN 115V 60HZ 3400 RPM 6.378 MTG HOLES . . . . . . . . . . . . . .
. . BASE,W/PEM STUDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SIDE,COOLER BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL,REAR COOLER BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHELL,COOLER BASE W/PEM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL,WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . . . .
. . FOOT,MTG UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
10
1
2
1
1
1
1
2
1
1
2
4
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 891 Page 90
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Cooler
. . . 15 . . . . . . . . . . 173955 . . TANK,WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . 166608 . . CAP,TANK SCREW−ON W/VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT PANEL ASSY,W/CMPNTS (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . +236810 . . . . PANEL,FRONT W/PEM STUDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . 219178 . . . . LABEL,CAUTION INCORRECT COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . 081543 . . . . FTG,COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . 238664 . . . . LIGHT,IND WHT LENS 125VAC SNAP−IN NEON NON−RELAMPA . . . . . .
. . . . . . . . . . . . . . . . 233159 . . . . SPACER,NYLON .312 OD X .194 ID X .500 LG . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . 215279 . . . . INDICATOR,FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . 188082 . . . . CABLE,POWER 2 FT 7 IN 16GA 3C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 204603 . . LABEL,COOLANT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 204604 . . LABEL,COOLANT IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . 236815 . . BRACKET,W/FILTER (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . 236816 . . . . BRACKET,TANK TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . 166564 . . . . FILTER,IN−LINE LOW PROFILE 100 SCREEN 3/8 HOSE BAR . . . . . . . . .
. . . 26 . . . . . . . . . . 178461 . . . . BRACKET,FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . 239494 . . SCREEN,FILTER LP CYL 100x100x0.0045 SST . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 228529 . . HOSE,RUBBER BRAIDED .375 ID X .650 OD X 19.500 . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 237152 . . HOSE,RUBBER BRAIDED .375 ID X .650 OD X 22.500 . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 237416 . . HOSE,COOLANT BRAIDED 10 IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
2
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 891 Page 91
. Hardware is
common and
not available unless listed.
7
6
8
9
10 11
4
1
12
13
12
11
10
14
5
2
15
3
38
32
33
34
37
31 − Figure 7-5
39
16
40
41
42
36
30
24
35
17
29
28
23
25
21
22
18
26
27
20
19
805 152-A
Figure 7-3. Single Wire Feeder
OM-236 891 Page 92
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Single Wire Feeder
. . . 1 . . . . . . . . . +234243 . . WRAPPER,SINGLE FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . 134464 . . LABEL,WARNING GENERAL PRECAUTIONARY STATIC&WIRE FE . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL ASSY,PCB SUPPORT (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . 236556 . . . . PANEL,PC BOARD SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 198122 . . . . STAND−OFF SUPPORT,PC CARD .250W/POST&LOCK .500 . . . . . . . . . .
. . . 4 . . . PC1 . . 233967 . . . . CIRCUIT CARD ASSY,PIPEWORX FEEDER MTR CTRL . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . 010494 . . . . BUSHING,SNAP−IN NYL 1.375 ID X 1.750 MTG HOLE . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . 143160 . . HUB+SPINDLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . 058427 . . . . RING,RETAINING SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . 180573 . . . . SHAFT ASSY,SUPPORT SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . 010233 . . . . SPRING,CPRSN .970 OD X .120 WIRE X 1.250 PLD . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . 057971 . . . . WASHER,FLAT .632IDX1.500ODX.125T STL PLD .175KEY . . . . . . . . . . . .
. . . 11 . . . . . . . . . . 010191 . . . . WASHER,FLAT .656IDX1.500ODX.125T FBR . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . 058628 . . . . WASHER,BRAKE STL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . 058428 . . . . HUB,SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . 071730 . . . . TUBING,STL .875 OD X12GA WALL X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . 135205 . . . . NUT, 625−11 .94HEX .77H STL PLD ELASTIC STOP NUT . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . 200556 . . SUPPORT,SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . 233559 . . BASE,FEEDER W/PEM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . 134306 . . FOOT,RUBBER 1.250 DIA X 1.375 HIGH NO 10 SCREW . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . 238518 . . LABEL,SINGLE FEEDER LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL,FRONT W/CMPNTS SINGLE BENCH FEEDER (INCLUDES) . . . . .
. . . 20 . . . PC2 . . 233899 . . . . CIRCUIT CARD ASSY,UI W/PROGRAM FEEDER . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . 236261 . . . . OVERLAY,SINGLE FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . 234501 . . . . BEZEL,FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . 213134 . . . . KNOB,ENCODER 1.670 DIA X .250 ID PUSH ON W/SPRING . . . . . . . . . .
. . . 24 . . . . . . . . . . 233560 . . . . PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . PLUG ASSY,TRIGGER LH (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG17 . 115093 . . . . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . RC2 . . 048282 . . . . . RCPT W/SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . . . . . . . . . PLUG ASSY,REMOTE (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . RC4 . . 222857 . . . . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG35 . 115093 . . . . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 200822 . . . . . HOUSING PLUG+PINS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . 000527 . . . . BLANK,SNAP−IN NYL .875 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . 159647 . . INSULATOR,MOTOR CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . 159360 . . INSULATOR,SCREW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . 125473 . . HOSE,SAE .187 ID X .410 OD X 27.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . 201762 . . DRIVE ASSY,WIRE S/L 4 ROLL W/TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . 145639 . . STRIP,BUNA−N .062 X 3.000 X 4.000 COMPRESSED SHT . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . 156243 . . CLAMP,MOTOR TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . 234426 . . KNOB,W/EXTENSION (LH) CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . 159646 . . CLAMP,MOTOR BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
7
1
3
1
1
1
1
2
2
2
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
4
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-236 891 Page 93
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Single Wire Feeder
. . . . . . . . . . . . . . . . . . . . . . . . . . . REAR PANEL ASSY,SINGLE FEEDER (INCLUDES) . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . PC3 . . 233919 . . . . CIRCUIT CARD ASSY,PS/FEEDER INTERFACE . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . GS1 . . 228036 . . . . VALVE, 24VAC 1WAY .750−14 THD 2.0MM ORF 100 PSI . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . 220805 . . . . NUT, 750−14 NPS 1.48HEX .41H NYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . 211989 . . . . FITTING,W/SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . 030170 . . . . BUSHING,SNAP−IN NYL .750 ID X 1.000 MTG HOLE . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . 239737 . . . . RECEPTACLE,BANANA JACK BLK 10−32 BINDING POST . . . . . . . . . . . .
. . . 42 . . . . . . . . . . 238498 . . . . ENCLOSURE,REAR SINGLE FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 074481 . . . . LABEL,LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 106410 . . . . LABEL,TO POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 215467 . . . . LABEL,VOLT SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 151026 . . KIT,DRIVE ROLL .035 V−GR 4 ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
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-236 891 Page 94
. Hardware is
common and
not available unless listed.
11
10
9
7
6
5
8
6
7
5
4
16
17
12
2
13 14
13
15
39
39
38
3
1
44
43
38
37
35
36
34
31 −
Figure 7-5
26
25
24
33 32
42
40
18
28
30 − Figure 7-5
41
29
27
23
19
20
21
22
805 150-A
Figure 7-4. Dual Wire Feeder
OM-236 891 Page 95
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Dual Wire Feeder
. . . 1 . . . . . . . . . . 142838 . . BRACKET,MTG SPOOL RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . 143160 . . HUB+SPINDLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . 135205 . . . . NUT, 625−11 .94HEX .77H STL PLD ELASTIC STOP NUT . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . 071730 . . . . TUBING,STL .875 OD X12GA WALL X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . 057971 . . . . WASHER,FLAT .632IDX1.500ODX.125T STL PLD .175KEY . . . . . . . . . . . .
. . . 6 . . . . . . . . . . 010191 . . . . WASHER,FLAT .656IDX1.500ODX.125T FBR . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . 058628 . . . . WASHER,BRAKE STL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . 058428 . . . . HUB,SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . 010233 . . . . SPRING,CPRSN .970 OD X .120 WIRE X 1.250 PLD . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . 180573 . . . . SHAFT ASSY,SUPPORT SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . 058427 . . . . RING,RETAINING SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . 141411 . . SUPPORT,SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . 211989 . . . . FITTING,W/SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . 239737 . . . . RECEPTACLE,BANANA JACK BLK 10−32 BINDING POST . . . . . . . . . . . .
. . . 15 . . . . . . . . . . 030170 . . . . BUSHING,SNAP−IN NYL .750 ID X 1.000 MTG HOLE . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . 233559 . . BASE,FEEDER W/PEM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . 134306 . . FOOT,RUBBER 1.250 DIA X 1.375 HIGH NO 10 SCREW . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . 238513 . . LABEL,DUAL FEEDER LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL,FRONT W/CMPNTS DUAL BENCH FEEDER (INCLUDES) . . . . . . .
. . . 19 . . . PC2 . . 233899 . . . . CIRCUIT CARD ASSY,UI W/PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . 234500 . . . . OVERLAY,FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . 234501 . . . . BEZEL,FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . 213134 . . . . KNOB,ENCODER 1.670 DIA X .250 ID PUSH ON W/SPRING . . . . . . . . . .
. . . 23 . . . . . . . . . . 233560 . . . . PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . . . . . . . . . . PLUG ASSY,TRIGGER LH (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG17 . 115093 . . . . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . RC2 . . 048282 . . . . . RCPT W/SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . PLUG ASSY,REMOTE (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . RC4 . . 222857 . . . . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG35 . 115093 . . . . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 200822 . . . . . HOUSING PLUG+PINS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . . . . . . . . . PLUG ASSY,TRIGGER RH (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . L 2 . . 213030 . . . . . CORE,TOROIDAL 19.00MM ID X 29.01MM OD X 7.62MM TH . . . . . . . .
. . . . . . . . PLG16 . 115093 . . . . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . RC3 . . 048282 . . . . . RCPT W/SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . 159647 . . INSULATOR,MOTOR CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . 159360 . . INSULATOR,SCREW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . 125473 . . HOSE,SAE .187 ID X .410 OD X 27.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . 201762 . . DRIVE ASSY,WIRE S/L 4 ROLL W/TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . 201768 . . DRIVE ASSY,WIRE R 4 ROLL W/TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . 145639 . . STRIP,BUNA−N .062 X 3.000 X 4.000 COMPRESSED SHT . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . 156243 . . CLAMP,MOTOR TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . 159646 . . CLAMP,MOTOR BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . 234424 . . KNOB,W/EXTENSION (RH) CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . 234426 . . KNOB,W/EXTENSION (LH) CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
2
4
4
4
2
2
2
2
1
2
1
2
1
4
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
8
2
1
1
2
2
2
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-236 891 Page 96
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Dual Wire Feeder
. . . . . . . . . . . . . . . . . . . . . . . . . . . REAR PANEL ASSY,DUAL FEEDER (INCLUDES) . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . PC3 . . 233919 . . . . CIRCUIT CARD ASSY,PS/FEEDER INTERFACE . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . 233561 . . . . ENCLOSURE,REAR DUAL FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . GS 1,
GS 2 . 228036 . . . . VALVE, 24VAC 1WAY .750−14 THD 2.0MM ORF 100 PSI . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . 220805 . . . . NUT, 750−14 NPS 1.48HEX .41H NYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 074479 . . LABEL,RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 074481 . . LABEL,LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 106410 . . LABEL,TO POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 215467 . . LABEL,VOLT SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . +233562 . . WRAPPER,DUAL FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . 134464 . . LABEL,WARNING GENERAL PRECAUTIONARY STATIC&WIRE FE . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL ASSY,PCB SUPPORT (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . 236556 . . . . PANEL,PC BOARD SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 198122 . . . . STAND−OFF SUPPORT,PC CARD .250W/POST&LOCK .500 . . . . . . . . . .
. . . 43 . . . . . . . . . . 010494 . . . . BUSHING,SNAP−IN NYL 1.375 ID X 1.750 MTG HOLE . . . . . . . . . . . . . . . .
. . . 44 . . . PC1 . . 233967 . . . . CIRCUIT CARD ASSY,PIPEWORX FEEDER MTR CTRL . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 237210 . . HOSE ASSY,GAS Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 143838 . . CABLE,WELD 26 IN 4/0 W/TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 151026 . . KIT,DRIVE ROLL .035 V−GR 4 ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 151053 . . KIT,DRIVE ROLL .045 VK−GR 4 ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
1
1
1
1
1
1
1
1
7
3
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-236 891 Page 97
. Hardware is common and
13
not available unless listed.
19
11
14
15
See Table 7-1 For
Drive Roll & Wire Guide Kits
1
2
3
4
5
16
17
7
6
18
9
8
19
12
10
20
11
21
22
37
34
23
24
25
26
36
35
27
33
28
32
30
31
29
3
4
5
6
2
1
803 790-A
Figure 7-5. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-5. Drive Assembly, Wire (Figure 7-3 Item 31
And Figure 7-4 Items 30 And 31)
. . . 1 . . . . . . . . . . . . . . . 010 668
. . . 2 . . . . . . . . . . . . . . . 172 075
. . . 3 . . . . . . . . . . . . . . . 149 962
. . . 4 . . . . . . . . . . . . . . . 149 486
. . . 5 . . . . . . . . . . . . . . . 132 750
. . . 6 . . . . . . . . . . . . . . . 150 520
. . . 7 . . . . . . . . . . . . . . . 133 493
. . . 8 . . . . . . . . . . . . . . . 133 350
. . . 9 . . . M1,101 . . . . 201 230
. . . . . . . . . . . . . . . . . . . . . 153 491
. . . . . . . . . . . . . . . . . . . . . 153 492
. . . . . . . . . . . . . . . . . . . . *153 493
. . . . . . . . . . . . . . . . . . . . . 184 136
. . . 10 . . . . . . . . . . . . . . . 155 098
. . . . . . . . . . . . . . . . . . . . . 153 550
. . . . . . . . . . . . . . . . . . . . . 155 099
. . . . . . . . . . . . . . . . . . . . . 155 100
. . . . . . . . . . . . . . . . . . . . . 154 031
. . . . . . . . . . . . . . . . . . . . . 133 493
OM-236 891 Page 98
. . Screw, Cap Stl Sch .250-20 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Carrier, Drive Roll W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Carrier Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Rotation Arm Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Flat Stl .257 Id X .619 Od X .105 . . . . . . . . . . . . . . . . . . . . . . .
. . Ring, Retaining Ext .250 Shaft X .025Thk . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Gear 1/8hp 24VDC Standard Speed . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Brush Replacement (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Cap, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Brush, Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Brush Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Cover Motor Gearbox (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cover, Motor Gearbox (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Gasket, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Screw, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ring, Rtng Ext .250 Shaft Grv X .025Thk . . . . . . . . . . . . . . . . . . . . . .
4
4
4
2
2
2
2
1
1
1
2
2
1
1
1
1
5
2
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-5. Drive Assembly, Wire (Continued)
.....................
.....................
. . . 11 . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . .
. . . 21 . . PC51,151 . . .
. . . . . . . . . . PLG5 . . . . .
.....................
. . . 22 . . . . . . . . . . . . . . .
.....................
. . . 23 . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . .
.....................
. . . 34 . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . .
203 642
203 631
203 641
182 415
203 640
182 156
182 155
132 746
203 633
203 632
133 739
203 637
237 048
131 204
604 311
132 611
603 115
167 387
168 825
133 308
134 834
149 959
179 265
179 264
108 940
604 538
151 437
151 290
179 277
178 937
601 872
602 213
602 243
601 966
. . Pressure Arm, R & Vert L 4 Roll (Includes) . . . . . . . . . . . . . . . . . . . . . . 1
. . Pressure Arm, S/L & Vert S/R 4 Roll (Includes) . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Flat Indicator Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Knob, W/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Carrier, Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Flat Buna .375 Id X .625 Od X .062Thk . . . . . . . . . . . . . . . 2
. . . . Knob, W/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . 1
. . Circuit Card Assy, Digital Tach (Includes) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Grommet, Rbr .250 Id X .375Mtg Hole .062 Groove . . . . . . . . . . . . . 1
. . Optical Encoder Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Weather Stripping, Adh .125 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ring, Retaining Ext .375 Shaft X .025Thk . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Sae .187 Id X .410 Od (order by ft) . . . . . . . . . . . . . . . . . . 2 Ft (0.6 m)
. . Fitting, Brs Barbed M 3/16Tbg X .312-24 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adapter, Gun/Feeder LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adapter, Gun/Feeder RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Cap Stl Hexhd .250-20 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Washer, Flat Stl Sae .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Knob, Plstc T 1.125 Lg X .312-18 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Mach Stl Hexwhd 10-32 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Cover, Drive Roll (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Cap Stl Hexhd .375-16 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
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-236 891 Page 99
Table 7-1. Drive Roll And Wire Guide Kits
Wire Size
Fraction
Metric
V-GROOVE
VK-GROOVE
Inlet Guide
Intermediate
Guide
4 Roll Kit
Drive Roll
4 Roll Kit
Drive Roll
.035 in.
0.9 mm
150 993
149 518
151 026
053 700
151 052
132 958
.045 in.
1.1/1.2 mm
150 994
149 519
151 027
053 697
151 053
132 957
.052 in.
1.3/1.4 mm
150 994
149 519
151 028
053 698
151 054
132 956
1/16 in.
(.062 in.)
1.6 mm
150 995
149 520
151 029
053 699
151 055
132 955
.068-.072 in.
1.8 mm
150 995
149 520
151 056
132 959
5/64 in.
(.079 in.)
2.0 mm
150 995
149 520
151 057
132 960
3/32 in.
(.094 in.)
2.4 mm
150 996
149 521
151 058
132 961
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along With 4 Drive Rolls.
OM-236 891 Page 100
. Hardware is
common and
not available unless listed.
5
4
6
5
7
1
2
3
9
8
11
9 10
12
805 302-b
Figure 7-6. Running Gear
OM-236 891 Page 101
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-6. Running Gear
. . . 1 . . . . . . . . . . 236827
. . . 2 . . . . . . . . . . . 238611
. . . 3 . . . . . . . . . . 236817
. . . 4 . . . . . . . . . +233666
. . . . . . . . . . . . . . . . 200285
. . . 5 . . . . . . . . . . 170647
. . . 6 . . . . . . . . . . 004214
. . . 7 . . . . . . . . . . 188441
. . . 8 . . . . . . . . . . 234359
. . . 9 . . . . . . . . . . 602250
. . . 10 . . . . . . . . . . 121614
. . . 11 . . . . . . . . . . 163463
. . . 12 . . . . . . . . . . 209479
..
..
..
..
..
..
..
..
..
..
..
..
..
HANDLE,POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAP,TUBE .865 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE,GUN HOLDER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,SUPPORT CYLINDER DUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING CYLINDER MAY EXPLODE IF DAMAGED . . . . . . . . . . . .
BUSHING,SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
BUSHING,SNAP−IN NYL 1.625 ID X 2.000 MTG HOLE . . . . . . . . . . . . . . . . .
CHAIN,WELDLESS 2/0 X 31. BRIGHT ZINC PLD . . . . . . . . . . . . . . . . . . . . . . .
RACK WHEEL ASSY, RUNNING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,FLAT .812IDX1.469ODX.134T STL PLD ANSI.750 . . . . . . . . . . . . .
RING,RTNG EXT .750 SHAFT X .085 THK E STYLE PLD . . . . . . . . . . . . . . .
WHEEL,RBR TIRE 10.000 OD X 2.000 WIDE X .750 BORE . . . . . . . . . . . . . .
CASTER,SWVL 5.00 IN URETHANE W/BRAKE 2.000 IN WIDE . . . . . . . . . .
2
4
1
1
1
2
1
2
1
4
2
2
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 891 Page 102
2
. Hardware is
common and
not available unless listed.
1
5
3
4
4
7
8
6
4
9
805 301-A / Ref. 239 780-B
Figure 7-7. Composite Cables
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
5 ft
25 ft
50 ft
300 367 300 454 300 456
Figure 7-7. Composite Cables
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
2
2
3
3
3
4
5
5
6
7
8
9
9
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
300508
300465
300466
238108
238109
238110
238111
238112
238432
238263
238264
210253
047636
143922
300461
300462
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
CABLE,INTERCONNECTING 5 FT . . . . . . . . . . . . . . . . . . 1
CABLE,INTERCONNECTING 31 FT . . . . . . . . . . . . . . . . . . . . . . . . 1
CABLE,INTERCONNECTING 56 FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE ASSY,GAS 33 FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOSE ASSY,GAS 58 FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE,WELD 4.5 FT 2/0 W/TERMS . . . . . . . . . . . . . . . . 1
CABLE,WELD 31 FT 2/0 W/TERMS . . . . . . . . . . . . . . . . . . . . . . . . 1
CABLE,WELD 56 FT 2/0 W/TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP,STRAIN RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
COVER,CABLE 28 FT (BLACK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COVER,CABLE 53 FT (BLACK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE TIE, 0−1.750 BUNDLE DIA . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
HOUSING PLUG + PINS,(SERVICE KIT) . . . . . . . . . . . . 2 . . . . 2 . . . .
CONN,CIRC CPC CLAMP STR RLF . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
CABLE,VOLT SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
CABLE,VOLT SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
2
2
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 891 Page 103
. Hardware is
common and
not available unless listed.
1
2
3
805 148-B
Figure 7-8. Cable Hanger Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-8. Cable Hanger Assembly
. . . 1 . . . . . . . . . . 285304 . . BRACKET,CABLE HOLDER W/EDGE TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . 238611 . . CAP,TUBE .865 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . 236826 . . TUBE,CABLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 891 Page 104
. Hardware is
common and
not available unless listed.
5
2
3
4
1
6
14
15
13
9
7
8
11
10
12
805 318-A
Figure 7-9. Feeder Cart
OM-236 891 Page 105
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-8. Cable Hanger Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
217255
234505
234546
234554
235121
234556
234553
163463
602250
121614
234545
123557
234555
237215
232470
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
SLIDE,DRAWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE ASSY, FEEDER CART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAB,LIFT SLOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHELF,UPPER,FEEDER CART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLDER,CABLE GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEG,REAR RH CART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE,CART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL,RBR TIRE 10.000 OD X 2.000 WIDE X .750 BORE . . . . . . . . . . . . . .
WASHER,FLAT .812ID X 1.469OD X .134T STL PLD . . . . . . . . . . . . . . . . . . .
RING,RTNG EXT .750 SHAFT X .085 THK E STYLE PLD . . . . . . . . . . . . . . .
SHELF,LOWER,FEEDER CART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CASTER,SWVL 5.00 IN POLYOLEFIN X 1.375 X .437−14 . . . . . . . . . . . . . . .
LEG,REAR LH CART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,DRAWER LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRAWER,ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
1
2
1
2
4
2
1
2
2
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 891 Page 106
Effective January 1, 2009
(Equipment with a serial number preface of LK or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
* Accessory (Kits)
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Fume Extractors
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* ICE Plasma Cutting Torches (No Labor)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
* Work Stations/Weld Tables (No Labor)
6 Months — Batteries
90 Days — Parts
* MIG Guns and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays, work station table tops and welding
curtains, or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend
models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
3.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2009−10
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2009 Miller Electric Mfg. Co.
2009−01
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