Miller | LJ370354V | Owner Manual | Miller XR-ALUMAFEED User manual

Miller XR-ALUMAFEED User manual
OM-239 210A
2009−01
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun
XR - AlumaFeed
™
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 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Connections With A Constant Voltage (CV) Or Constant Current/Constant Voltage (CC/CV) Welding
Power Source Having A 14-Socket Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Air-Cooled Feeder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Air-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Water-Cooled Feeder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Water-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Installing Wire Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Threading Welding Wire Through Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Setup Menu Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Setting A Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Setting A Crater Fill Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Profile Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Feeder Drive Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Replacing Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
1
1
1
3
4
4
4
5
5
5
7
8
9
9
11
11
12
13
13
13
13
14
15
16
17
18
18
19
20
20
21
22
22
23
23
24
25
26
27
28
28
29
29
30
32
34
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
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.
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.
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 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-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-239 210 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes 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 Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
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.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
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.
OM-239 210 Page 2
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 UNIT can cause injury.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
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.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine replacement parts from the
manufacturer.
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 cause injury.
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 cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D 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-239 210 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).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, 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, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, 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 10036–8002 (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,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, 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 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
2. Arrange cables to one side and away from the operator.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-239 210 Page 4
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About 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_2007−04
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.
D
D
D
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
D
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
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.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
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 Ne pas toucher aux pièces électriques sous tension.
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 Porter des gants isolants et des vêtements de protection secs et
sans trous.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
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 toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
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
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-239 210 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a
coupé l’alimentation.
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.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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 in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
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 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 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 Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
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 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 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 En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
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 pro
voquer des brûlures dans les yeux e
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 pendant le soudage
(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-239 210 Page 6
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
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 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 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.
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.
LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.
D Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.
D 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.
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.
LE BRUIT peut endommager l’ouïe.
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.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
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.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
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 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’APPAREIL peut
blesser.
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.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
LES ÉTINCELLES VOLANTES risquent de 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.
SUR-
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.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-239 210 Page 7
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
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.
DES ORGANES MOBILES peuvent
provoquer 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 Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
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 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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D N’utiliser que les pièces de rechange recommandées par le constructeur.
D
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D
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.
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-239 210 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).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, 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, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.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).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, 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,
11 West 43rd Street, New York, NY 10036-8002 (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).
2-6. Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
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-239 210 Page 9
OM-239 210 Page 10
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
A
B
1
1.1
2
2.1
3
3.1
4
4.1
5
+
C
1.2
2.2
1.3
2.3
3.2
+
3.3
+
+
6
S-178 936
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects clear.
1 Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
OM-239 210 Page 11
Spool Brake/Drive Roll Pressure
Label CE
1
2
3
Read the Owner’s Manual.
Do not overtighten wire spool
brake pressure. Tighten only
until wire does not overspool
from wire supply spool.
Do not overtighten drive roll
pressure. See Section 5-8 for
recommended tension
settings.
3-2. Symbols And Definitions
. Some symbols are found only on CE products.
A
IP
Amperes
X
Volts
Alternating Current
Hertz
Circuit Breaker
Wire Feed
Jog
Output
Trigger
Gun
Press To Set
Increase
Trigger Hold On
Trigger Hold Off
Purge
Spot Weld Time
Percent
Run-In
Load Voltage
Read Instructions
Rated Current
Line Connection
Water (Coolant) Input
Water (Coolant)
Output
Fuse
Continuous
Spot Welding
Press
Locked
MIG-Start
MIG-Crater
Degree Of
Protection
Burnback Time
I1
V
Hz
Primary Current
OM-239 210 Page 12
U1
I2
Primary Voltage
U2
Duty Cycle
SECTION 4 − INTRODUCTION
4-1. Specifications
Type of Input
Power
Welding Power
Source Type
24 Volts AC
Single-Phase
5 Amperes
50/60 Hertz
Constant Voltage (CV)
DC For GMAW Or
Constant Voltage(CV) /
Constant Current (CC) DC
For GMAW-P
All Need 14-Pin And
Contactor Control
Wire Feed
Speed Range
70 To 780 ipm (1.8
To 22.2 mpm)
Wire
Diameter
Range
0.035 To .062 in
(0.9 To 1.6 mm)
Max Spool
Capacity: 12 in
(305 mm)
Welding
Circuit Rating
Overall
Dimensions
Weight
Length: 21-1/4 in
(540 mm)
400 A
100% Duty Cycle *
Width: 9-1/2 in
(241 mm)
42.5 lb
(19.2 kg)
Height: 16 in
(406 mm)
* System Duty Cycle is Limited to Gun Rating
SECTION 5 − INSTALLATION
5-1. Connections With A Constant Voltage (CV) Or Constant Current/Constant Voltage
(CC/CV) Welding Power Source Having A 14-Socket Receptacle
9
1
2
7
8
6
3
5
5
Ref. 242 438-A / 805 349-A
4
1
2
3
4
CV Or CC/CV Welding Power Source
24 VAC/Contactor Control 14-Pin
Plug
Negative (−) Weld Cable
Workpiece
5
Welding Gun
9
6
Wire Feeder
Gas Cylinder
7
Positive (+) Weld Cable
. Shielding gas pressure not to exceed
8
Gas Hose
100 psi (689 kPa).
OM-239 210 Page 13
5-2. Air-Cooled Feeder Connections
1
Gas Fitting
Connect one end of 10 ft (3 m) gas
hose to rear of unit, gas solenoid fitting. Connect remaining end of
hose to regulator/flowmeter.
. Shielding gas pressure not to
exceed 100 psi (689 kPa).
2
Weld Cable To Welding Power
Source
Select and prepare weld cable
according to welding power source
manual.
3
4
5
2
Route one end of weld cable
through grommet, through reed
relay, and connect to weld cable terminal in feeder. Connect remaining
end of cable to positive (+) weld
output terminal on welding power
source.
5
4
Rear Panel
2
Weld Cable Grommet
Current Sensing (Reed) Relay
Weld Cable Terminal In
Feeder
5
Connect To 14-Socket
Receptacle On Welding
Power Source
Top View
1
3
Connect To Positive (+)
Weld Output Terminal On
Welding Power Source
Tools Needed:
9/16 in
Ref. 805 350-A
OM-239 210 Page 14
5-3. Air-Cooled Gun Connections
4
5
Left Side
3
2
Ref. 242 435-A / 805 352-A / 805 351-A
1
1 Gun Control Cable
Insert plug into Gun Control receptacle, and
tighten threaded collar.
2 Gun Power Pin
3
Gun Bushing
4
Gun Securing Knob
5
Drive Casting
Loosen gun securing knob and insert gun
power pin through gun bushing until it
bottoms against drive casting. Tighten
knob.
OM-239 210 Page 15
5-4. Water-Cooled Feeder Connections
Obtain coolant supply.
1
Gas Fitting
Connect one end of 10 ft (3 m) gas
hose to rear of unit, gas solenoid fitting. Connect remaining end of
hose to regulator/flowmeter.
. Shielding gas pressure not to
exceed 100 psi (689 kPa).
2
Weld Cable To Welding Power
Source
Select and prepare weld cable
according to welding power source
manual.
3
4
5
2
4
5
7
Rear Panel
2
Connect To 14-Socket
Receptacle On Welding
Power Source
6
5
Weld Cable Grommet
Current Sensing (Reed) Relay
Weld Cable Terminal In
Feeder
Route one end of weld cable
through grommet, through reed
relay, and connect to weld cable terminal in feeder. Connect remaining
end of cable to positive (+) weld
output terminal on welding power
source.
6
7
Coolant Hose Grommet
Location Of Coolant Fittings
On Front Panel
Route one end of a coolant hose
through grommet, and connect to
rear of Coolant Out fitting in feeder.
Connect remaining end to supply
fitting on coolant supply.
Top View
Route one end of remaining coolant
hose through grommet, and connect to rear of Coolant In fitting in
feeder. Connect remaining end of
hose to return fitting on coolant
supply.
1
3
Connect To Positive (+)
Weld Output Terminal On
Welding Power Source
Application
GMAW Or Where Coolant
Contacts Aluminum Parts Or
Where HF* Not Used
MILLER Aluminum Protecting
Coolant No. 043 809**;
Distilled Or Deionized Water OK
Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
OM-239 210 Page 16
Tools Needed:
9/16 in
Ref. 152 431-A / Ref. 805 350-A
5-5. Water-Cooled Gun Connections
. Turn on coolant supply before
welding or gun will be damaged.
1
Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.
3
4
2
3
4
5
Loosen gun securing knob, and
insert gun power pin through gun
bushing until it bottoms against
drive casting. Tighten knob. Close
and latch door.
6
5
9
Gun (Coolant) “In” Hose
Connect to Water “In” fitting on
feeder (left-hand threads).
7
Gun (Coolant) “Out” Hose
Connect to Water “Out” fitting on
feeder (left-hand threads)
Left Side
8
Gun Power Pin
Gun Securing Knob
Gun Bushing
Drive Casting
8
9
10
11
Water Cooler Output
Water Cooler Input
Feeder (Coolant) Output
Feeder (Coolant) Input
10
11
4
Tools Needed:
7
9/16 in
6
2
1
Ref. 242 439-A / 805 353-A / 805 351-A / 805 106-A
OM-239 210 Page 17
5-6. 14-Pin Plug Information
Pin*
I
G
A
24 volts AC with respect to socket G.
B
Contact closure to A completes 24 volts AC contactor control circuit.
A
G
Circuit common for 24 volts AC circuit.
B
L C
M D
E
C
+10 volts DC input from power source to wire feeder with respect to socket D.
D
Remote control circuit common.
E
0 to +10 volts DC output signal from wire feeder to power source with respect to socket D.
H
Voltage feedback; 0 to +10 volts DC, 1 volt per 10 arc volts.
F
Current feedback; 0 to +10 volts DC, 1 volt per 100 amperes.
L
0 to +10 volts DC output signal from wire feeder to power source with respect to socket N.
N
Feeder common.
M
0 to +10 volts DC output signal from wire feeder to power source with respect to socket N.
J
H
K
N
F
Pin Information
*The remaining pins are not used.
5-7. Installing Wire Spool
1
2
3
4
5
Wire Spool
Hub
Hub Pin
Notch
Retaining Ring
Slide spool onto hub so wire feeds
off bottom. Turn spool until hub pin
fits hole in back of spool (notch on
hub aligns with hub pin for guidance). Reinstall retaining ring.
Thread welding wire
(see Section 5-8).
3
3
2
4
1
5
Tools Needed:
Ref. 805 350-A / 072 573-B
OM-239 210 Page 18
5-8. Threading Welding Wire Through Feeder
1
Tools Needed:
. Hold wire tightly to keep
it from unraveling.
6 in
(150 mm)
1
Pull and hold wire; cut off end.
Tension Arm
Open tension arm.
1
Install proper size drive rolls.
Thread wire thru inlet guide, along drive roll groove, and
into wire conduit. Close tension arm. Adjust tension as
follows:
Tension Settings
Wire Size
0.035 in.
Welding
1−2
0.040 in.
3/64 in.
Gun Calibration
3−4
3−4
1/16 in.
Ref. 805 350-A / 242 517-A
OM-239 210 Page 19
SECTION 6 − OPERATION
6-1. Controls
10
11
12
13
9
14
8
15
16
7
SETUP
6
START
SCHD B
CRATER
ADVTRIG
17
18
5
4
3
19
2
20
SETUP
START
CRATER
1
21
GUN
WATER IN
WATER OUT
JOG / PURGE
GUN CONTROL
805 354-A
1
2
3
4
5
6
7
Start Button
Setup Button
Setup Indicator
Start On Indicator
Left Adjust Knob
Arc Length Indicator
Volts Indicator
OM-239 210 Page 20
8
9
10
11
12
13
14
Crater Menu Indicator
Start Menu Indicator
Left Display
Lock Indicator
Setup Menu Indicator
Right Display
Schedule B Indicator
15
16
17
18
19
20
21
Advanced Trigger Indicator
Wire Speed Indicator
Amps Indicator
Right Adjust Knob
Crater On Indicator
Crater Button
Jog/Purge Switch
6-2. Operational Terms
The following is a list of terms and their definitions as they apply to the wire feeder:
General Terms:
MIG
CV weld process with individual settings of voltage and wire speed.
Pulsed MIG
CC weld process with factory taught data using peak and background current, pulse width and pulses
per second. Adaptive pulse control methods modulate one or more of the taught data parameters to
regulate or maintain a fixed arc length.
Synergic
Refers to the system’s ability to match the power setting to the set wire feed speed using a single
knob control. In synergic Pulsed MIG, the pulse parameters are automatically increased or decreased
to match the power output to the set wire speed.
Non- Synergic
Refers to independent control of wirefeed speed and power output. In non−synergic mode, increasing
or decreasing the set wirefeed speed requires corresponding adjustment of the arc length or voltage
setting.
2T
Basic trigger function, weld sequence starts when the trigger is pressed and ends when the trigger is
released.
Trigger Hold
Trigger function allowing the operator to weld without continuously pressing the gun trigger. In Trigger
Hold mode, momentarily press the gun trigger until an arc is established, and welding will continue
until the gun trigger is momentarily pressed again.
4T
Trigger function enabling selection between Start, Weld and Crater parameters using the gun trigger.
Start and Crater are automatically active and cannot be turned off in 4T mode. In 4T mode, press and
hold the gun trigger to begin welding at the Start parameter settings. Release the gun trigger, and
welding will continue at the Weld parameter settings. Press and hold the gun trigger again, and welding continues at the Crater parameter settings. The Crater sequence ends when the gun trigger is
released and the Crater parameter times out.
If the gun trigger is pressed again before the Crater parameter times out, the Crater time is reset and
welding continues at the Weld parameter settings until the gun trigger is released. When the trigger is
released, welding continues at the Crater parameter settings until the Crater parameter times out.
Spot
Trigger function that automatically shuts the weld off after a set amount of time. The weld will end
when the set time has expired or the trigger has been released, which ever occurs first. The spot time
is reset when the trigger is released.
Arc Length
Refers to physical distance between wire electrode and molten puddle. Term also used to represent
adjustments in the Pulsed MIG weld process.
Dual Schedule
Allows selecting a pair of weld parameter settings that can be used together.
Preflow
The amount of time that the shielding gas will flow after the trigger is pressed and before the welding
arc will be allowed to be active.
Postflow
The amount of time that the shielding gas will flow after the arc has been shut off.
Start
Provides voltage/arc length, wire feed speed and time values for modified arc start.
Crater
Provides voltage/arc length, wire feed speed and time values for modified arc end.
OM-239 210 Page 21
6-3. Jog/Purge
Pressing the Jog/Purge switch allows the
operator to jog wire without energizing the
weld power or gas valve circuit.
S The feeder provides the ability to jog the
wire by means of the gun trigger or the Jog/
Purge switch. If the welding arc does not
initiate in 3 seconds after the gun trigger is
activated, the feeder will perform a jog operation for a maximum of 2 minutes. If the
gun trigger is still activated after 2 minutes,
the jog operation is terminated to prevent
complete unspooling of the wire, in the
case of a damaged gun (see Section 8-3).
S Jog speed is the wirefeed speed the unit
is set to for welding.
S Jogging can also be accomplished by
pressing the Jog/Purge button.
S Pressing the Jog/Purge button also allows the operator to purge gas lines before
welding and to preset gas pressure at the
regulator.
6-4. Quick Setup Guide
Menu Item
Menu Item Values
Description
WIRE
0.035. 0.040, 3/64, 1/16 in.
Wire size setting
MAN
MIG or Non-Synergic Pulsed MIG
AUTO
Synergic Pulsed MIG
VOLT
Display setting for MIG
PWR.S
DISP
ARC.L/VOLT
Press and hold the SETUP button.
Release the SETUP button when SETUP
is shown.
Rotate the LEFT ADJUST KNOB to select
the menu items and use the RIGHT
ADJUST KNOB to change menu item values.
Confirm the menu item values listed in the
table above, set accordingly for the welding
process and wire size being used.
Press the Setup Button to exit the menu.
MIG Operation
When setup for MIG welding, VOLTS is lit
under the Left Display and the WIRE
SPEED INDICATOR is lit under the Right
Display. The voltage is adjusted using the
Left Adjust Knob and the wire speed is adjusted using the potentiometer in the gun
OM-239 210 Page 22
Set to match power source display for Non-Synergic or Synergic Pulsed MIG
handle.
Non−synergic Pulsed MIG Operation
ment range is dependent on the pulse program selection at the power source.
When setup for Non−synergic Pulsed MIG
welding, the selected DISP parameter
(ARC.L or VOLT) is lit under the Left Display and the WIRE SPEED INDICATOR is
lit under the Right Display. The arc length
or voltage is adjusted using the Left Adjust
Knob and the wire speed is adjusted using
the potentiometer in the gun handle. The
Arc Length or Voltage setting corresponds
to the amount of energy required to burn off
the welding electrode. As wire feed speed
increases, a higher arc length or voltage
setting is required to burn off the additional
wire. Likewise, a lower arc length or
voltage setting is required as wire feed
speed is decreased. In Non−Synergic
Pulsed MIG, the arc length adjustment
range is 0.0 to 100.0 and the voltage adjust-
When setup for Synergic Pulsed MIG welding, the selected DISP parameter (ARC.L
or VOLT) is lit under the Left Display and
the WIRE SPEED INDICATOR is lit under
the Right Display. The arc length or voltage
is adjusted using the Left Adjust Knob and
the wire speed is adjusted using the potentiometer in the gun handle. In Synergic
Pulsed MIG, the Arc Length adjustment
range is 0 − 100. The pulse programs have
been developed at an arc length setting of
50. Increasing the arc length setting increases the actual arc length, and decreasing the setting decreases the actual
arc length. It is not necessary to change the
arc length setting when changing wire feed
speed.
Synergic Pulsed MIG Operation
SECTION 7 − PROGRAMMING
7-1. Setup Menu
To enter the SETUP MENU press and release the SETUP button. The SETUP
MENU INDICATOR and the SETUP
BUTTON INDICATOR will illuminate.
Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT
DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown
in the RIGHT DISPLAY.
To exit the SETUP MENU press and release the SETUP button.
Items that can be adjusted in this menu are:
Trigger Control (TRIG) − Sets the gun
trigger control. The trigger control can be
configured as (2T, HOLD, 4T, SPOT). See
Section 6-2.
Trigger Hold Delay (HOLD) − Additional
trigger setting only appearing in the menu
when the trigger control is set to (TRIG
HOLD). Trigger hold delay time is the minimum amount of time the trigger must be
held for trigger hold to become active.
There is a built in maximum trigger hold
time which the trigger must be released
within for trigger hold to become active.
The maximum trigger hold time is always
4.0 seconds after the trigger hold delay
time. For Example, if the trigger hold delay
time is set to 2.0 seconds, the trigger must
be held for at least 2.0 seconds and released within 6.0 seconds for trigger hold to
become active. Once the trigger hold function is active, the wire feeder will continue
feeding wire until the trigger is pressed and
released again.
Preflow (PRE) − The amount of time that
the shielding gas will flow after the trigger
is pressed and before the welding arc will
be allowed to be active. Range of this setting is from (0.0 to 5.0) seconds.
Postflow (POST) − The amount of time
that the shielding gas will flow after the arc
has been shut off. Range of this setting is
from (0.0 to 10.0) seconds.
Run−In Speed (R−IN) − The wirefeed
speed prior to the welding arc being struck.
This setting is a percentage of the wirefeed
speed the unit is set to for welding. Range
of this setting is from (X0.10 to X0.99 to
OFF). Example: If the weld wirefeed speed
is 200 and R−IN is X0.50, the run−in
wirefeed speed is 100.
. Additional
PROFILE PULSE menu
items may appear in the SETUP
MENU when PROFILE PULSE is active. See Section 7-5.
Notes
OM-239 210 Page 23
7-2. Setup Menu Level 2
To enter the SETUP MENU LEVEL 2 press
and hold the SETUP button. The SETUP
MENU INDICATOR and the SETUP
BUTTON INDICATOR will illuminate.
process. If the power source weld process
is set to PULSED MIG, the minimum
voltage range limit setting will change if the
wire and gas program selection is changed.
VOLTS INDICATOR illuminated. When set
to (ARC.L), the preset arc length will be
shown in the Left Display with the ARC
LENGTH INDICATOR illuminated.
Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT
DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown
in the RIGHT DISPLAY.
Voltage Range Limit (MAX) − Indicated in
the LEFT DISPLAY with the VOLTS
INDICATOR illuminated. Sets the maximum voltage. Range of this setting is dependent on the power source voltage range in
the MIG process, and varies with the selected wire and gas program in the PULSED
MIG process. If the power source weld process is set to PULSED MIG, the maximum
voltage range limit setting will change if the
wire and gas program selection is changed.
Dual Schedule Mode (SCHD) − Allows selecting a pair of weld parameter settings
that can be used together. When set to
(OFF), dual schedule is disabled. When set
to (TRIG), the active schedule is selected
with the gun trigger.
To exit the SETUP MENU LEVEL 2 press
and release the SETUP button.
Items that can be adjusted in this menu are:
Parameter Lock (LOCK) − When set to
(ON), the Preflow, Postflow, Run−In, Start,
and Crater parameters are locked and cannot be adjusted. Attempting to change a
locked parameter causes the display to momentarily display (LOCK).
Range Limits (LMTS) − When set to (ON),
the wirefeed speed and arc length or
voltage weld settings are limited to minimum and maximum adjustable ranges. The
minimum and maximum range settings appear next in the menu when (LMTS) is set
to (ON). When set to (OFF), range limits are
inactive and do not appear in the menu.
Wirefeed Range Limit (MIN) − Indicated in
the LEFT DISPLAY with the WIREFEED
SPEED INDICATOR illuminated. Sets the
minimum wirefeed speed. Range of this
setting is from 70 to 780 IPM.
Wirefeed Range Limit (MAX) − Indicated
in the LEFT DISPLAY with the WIREFEED
SPEED INDICATOR illuminated. Sets the
maximum wirefeed speed. Range of this
setting is from (MIN) setting to 780 IPM.
Arc Length Range Limit (MIN) − Indicated
in the LEFT DISPLAY with the ARC
LENGTH INDICATOR illuminated. Sets the
minimum arc length. Range of this setting is
from 0 to 100.
Arc Length Range Limit (MAX) − Indicated in the LEFT DISPLAY with the ARC
LENGTH INDICATOR illuminated. Sets the
maximum arc length. Range of this setting
is from (MIN) setting to 100.
. When the DISP option in the SETUP
MENU LEVEL 2 is set to (VOLT), the
Arc Length Range Limits are replaced
by Voltage Range Limits.
Voltage Range Limit (MIN) − Indicated in
the LEFT DISPLAY with the VOLTS
INDICATOR illuminated. Sets the minimum
voltage. Range of this setting is dependent
on the power source voltage range in the
MIG process, and varies with the selected
wire and gas program in the PULSED MIG
OM-239 210 Page 24
Wire Size (Wire) − Set to the appropriate
wire size being used for optimal wirefeed
consistency and speed accuracy.
Gun Type (GUN) − Indicates the gun type
detected. This setting is for information only
and cannot be adjusted.
Gun Calibration (G.CAL) − Calibrates the
gun motor to improve wirefeed speed accuracy. A gun calibration is recommended
during installation or when changing guns.
To perform a calibration, connect the gun to
the feeder and thread the wire thru the contact tip. Set the drive roll tension setting to
3-4 (see Section 5-8). Press and hold the
gun trigger. The feeder will begin feeding
wire with the power source output off. The
display will show (G.CAL HOLD) while the
calibration is active. When the calibration is
complete, wire feeding will stop and the display will show (G.CAL DONE).
If the calibration was unable to complete
successfully, a diagnostic error message
will appear (see Section 8-3).
Power Source Synergic Mode (PWR.S) −
Sets the synergic mode to (AUTO) or
manual (MAN). When set to (AUTO), the
wirefeeder and a synergic capable power
source function as a synergic Pulsed MIG
system. When set to (MAN), the power
source and wirefeeder function as a non−
synergic MIG or Pulsed MIG welding system.
S For proper operation, this setting should
be set to match the power source pulse
(PULS) mode setting.
Display (DISP) − Allows the preset weld
parameter adjustment to be set as voltage
or arc length. This setting effects only the
display appearance and will not effect operation. The (DISP) setting should be set to
match the power source display. When set
to (VOLT), the preset voltage set point will
be shown in the Left Display with the
. The SCHD B INDICATOR is illumin-
ated when the active schedule is set to
schedule B. Setup, Start, Crater, and
parameter settings can all be set independently within schedules.
. When
using Schedule B, wire feed
speed can only be set at the feeder using the Right Adjust Knob. Wire feed
speed adjustment at at the gun works
in Schedule A only.
Profile Pulse Menu (PROF) − Allows Profile Pulse to appear in the Setup Menu.
When set to (NO), (PROF) will not appear
in the Setup Menu. When set to (YES),
(PROF) will appear in the Setup Menu.
Menu Lock Code (CODE) − Allows setting
a numerical password code to obstruct access to the Setup Menu Level 2. By default,
(CODE) is (OFF) allowing access to the
menu without entering a password. The
password can be programmed to values
between 0 and 999. Once programmed, the
password must be re−entered each time
the menu is accessed. A failed password
attempt causes the display to momentarily
show (CODE FAIL). (CODE) will continue
to show on the display until the correct
password is entered or the power is cycled.
. Anytime
the menu is exited with
(CODE OFF), a special sequence is
required before a new password can
be set. With (CODE OFF) shown on
the display, press and hold the SETUP
button and rotate the RIGHT ADJUST
KNOB to set the password to (0123).
Release the SETUP button, the display
should read (CODE 0000). The password can now be set to a new value.
Product Version Information (INFO) −
Provides information about the firmware revision levels for the Motor Control and the
User Interface PCB’s. The default value is
(INFO NONE). To read the firmware versions rotate the Right Adjust Knob until the
display reads (INFO MOTR) or (INFO
FRNT). The corresponding firmware revision level will momentarily appear following
a short delay.
7-3. Setting A Start Sequence
To turn on a Start sequence, press the
START button. The START ON
INDICATOR will illuminate indicating Start
is active.
To turn off the Start sequence, press the
START button. The START ON
INDICATOR will turn off indicating Start is
inactive.
. The factory default mode for Start is
(AUTO). The (AUTO) setting has preset parameters. Start can also be set to
(MAN) for manual settings. The Start
mode can be changed in the START
MENU.
To enter the START MENU press and hold
the START button until the START MENU
INDICATOR illuminates.
Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT
DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown
in the RIGHT DISPLAY.
To exit the START MENU, press and re-
lease the START button.
Items that can be adjusted in this menu are:
Start Mode (STRT) − Sets the Start Mode
to (AUTO or MAN). When the Start mode is
set to (AUTO), factory default parameters
are used. The (AUTO) parameter values
appear in the menu but are not adjustable.
When the Start Mode is set to (MAN), each
of the parameters are adjustable.
Start Wirefeed Speed (WFS) − Sets the
wirefeed speed used during the Start Time.
This setting is a percentage of the wirefeed
speed the unit is set to for welding. Range
of this setting is from (X0.5 to X2.50).
Example: If the weld wirefeed speed is 200
and WFS is X1.50, the Start Wirefeed
Speed is 300.
Start Arc Length (ARC.L) − Sets the arc
length longer or shorter during the Start
Time. This setting is a percentage of the arc
length the unit is set to for welding. Range
of this setting is from (X0.50 to X1.50).
Example: If the weld arc length is set to 50
and ARC.L is X0.50, the Start Arc Length is
25.
. When the DISP option in the SETUP
MENU LEVEL 2 is set to VOLT, the
Start Arc length setting will be replaced
by the Start Voltage (VOLT) setting.
Start Voltage (VOLT) − Sets the voltage
during the Start Time. Range of this setting
is dependent on the power source voltage
range in the MIG process, and varies with
the selected wire and gas program in the
PULSED MIG process. If the power source
weld process is set to PULSED MIG, the
Start Voltage setting will change if the wire
and gas program selection is changed.
Start Time (TIME) − The amount of time the
wirefeed speed is active at the Start setting.
Range of this setting is from (0.1 to 0.5)
seconds.
Start Ramp Time (RAMP) − The amount of
time it takes to transition from the Start to
the weld wirefeed speed setting. Range of
this setting is from (0.1 to 5.0) seconds.
OM-239 210 Page 25
7-4. Setting A Crater Fill Sequence
To turn on Crater Fill, press the CRATER
button. The CRATER ON INDICATOR will
illuminate indicating Crater Fill is active.
lease the CRATER button.
To turn off Crater Fill, press the CRATER
button. The CRATER ON INDICATOR will
turn off indicating Crater Fill is inactive.
Crater Mode (CRTR) − Sets the Crater
mode to (AUTO or MAN). When the Crater
mode is set to (AUTO), factory default parameters are used. The (AUTO) parameter
values appear in the menu but are not adjustable. When the Crater mode is set to
(MAN), each of the parameters are adjustable.
. The factory default mode for Crater Fill
is (AUTO). The (AUTO) setting has
preset parameters. Crater Fill can also
be set to (MAN) for manual settings.
The Crater mode setting can be
changed in the CRATER MENU.
. The Crater Tack Time (TACK) is adjustable in both AUTO and MAN
modes.
To enter the CRATER MENU press and
hold the CRATER button until the CRATER
MENU INDICATOR illuminates.
Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT
DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown
in the RIGHT DISPLAY.
To exit the CRATER MENU press and re-
OM-239 210 Page 26
Items that can be adjusted in this menu are:
Crater Wirefeed Speed (WFS) − Sets the
Crater Fill wirefeed speed. This setting is a
percentage of the wirefeed speed the unit is
set to for welding. Range of this setting is
from (X0.30 to X1.00). Example: If the weld
wirefeed speed is 200 and WFS is X0.50,
the Crater Wirefeed Speed is 100.
Crater Arc Length (ARC.L) − Sets the arc
length longer or shorter during the CraterFill
Time. This setting is a percentage of the arc
length the unit is set to for welding. Range
of this setting is from (X0.50 to X1.50).
Example: If the weld arc length is set to 50
and ARC.L is X0.50, the Crater Arc Length
is 25.
. When the DISP option in the SETUP
MENU LEVEL 2 is set to VOLT, the
Crater Arc Length setting will be replaced by the Crater Voltage (VOLT)
setting.
Crater Voltage (VOLT) − Sets the voltage
during the Crater Fill time. Range of this setting is dependent on the power source in the
MIG process, and varies with the selected
wire and gas program in the PULSED MIG
process. If the power source weld process
is set to PULSED MIG, the Crater Voltage
setting will change if the wire and gas program selection is changed.
Crater Ramp Time (RAMP) − The amount
of time it takes to transition from the weld to
the Crater wirefeed speed setting. Range of
this setting is from (0.1 to 5.0) seconds.
Crater Fill Time (TIME) − The amount of
time the wirefeed speed is active at the
Crater setting. Range of this setting is from
(0.1 to 5.0) seconds.
Crater Tack Time (TACK) − This setting is
for tack welding without crater fill. The
Crater fill will not be active if the arc time is
less than the set time. Range of this setting
is from (0.1 to 5.0) seconds.
7-5. Profile Pulse
Profile Pulse optimizes Aluminum weld
bead appearance by producing welds with
consistently spaced ripple patterns, similar
to GTAW. This feature has been designed
to operate in a Synergic Pulsed MIG system. The consistent ripple pattern is
achieved by periodically changing both the
wirefeed speed and power level. The average wirefeed speed is determined by the
value the unit is set to for welding.
. By default, Profile Pulse parameters
are hidden from the Setup Menu. To
view the parameters, the (PROF) setting in the Setup Menu Level 2 must be
set to (YES). See section 7-2.
Profile Pulse Items that can be adjusted in
the Setup Menu are:
Profile Pulse ON/OFF (PROF) − Allows
Profile Pulse to be turned on or off.
Profile Pulse Frequency (P.FRQ) − Sets
the spacing between ripples in the weld
bead. Range of this setting is from (0.1 to
5.0) pulses per second. See Figures 1 and
2 below.
Profile Pulse Wirefeed Speed Change
(P.WFS) − Sets the percentage of change
above and below the wirefeed speed the
unit is set to for welding. Range of this setting is (X0.00 to X0.30). Example: If the
wirefeed speed is 200 and (P.WFS) is set to
(X0.10), the wirefeed speed will alternate
between 180 and 220 ipm.
Profile Pulse Arc Length (P.AL) − Sets an
arc length correction factor for the lower
wirefeed speed. This setting is a percentage of the arc length the unit is set to for
welding. Range of this setting is from (X0.5
to X1.5). Example: If the arc length for welding is set to 50 and (P.AL) is set to (X1.1),
the arc length setting for the lower wirefeed
speed is 55.
Figure 1
Constant travel speed with P.FRQ set to 0.1
Figure 2
Constant travel speed with P.FRQ set to 5.0
OM-239 210 Page 27
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
!
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
3 Months
Clean
And
Tighten
Weld
Terminals
Replace
Damaged Or
Unreadable
Labels
Replace Damaged
Gas Hose
Repair Or Replace
Cracked Cables
And Cords
6 Months
Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
8-1. Feeder Drive Assembly Maintenance
Retract wire onto spool.
1
1
2
3
4
Pressure Roll Assembly
Drive Motor Shaft
Drive Roll
Screw
Use wire brush to clean drive roll.
5
6
5
Drive Roll Idler
Shoulder Washers
Use wire brush to clean idler.
7
8
Outlet Guide
Wire Inlet Guide
Pull guide toward rear of feeder to
remove. Install new guide.
Thread welding wire and adjust
drive roll pressure, if necessary
(see Section 5-8).
6
8
7
Drive roll and idler are available for
the following wire size ranges:
.035 wire size
2
.040 wire size
Tools Needed:
5/16 in
.047 wire size
3
.062 wire size
4
When changing wire size, change
control box drive roll and idler, gun
pressure roll and drive roll.
805 350-A
OM-239 210 Page 28
8-2. Replacing Hub Assembly
Remove gun top cover and release
pressure arm.
Retract wire onto spool and remove
spool. Take hub apart as shown.
1
2
3
4
5
6
7
8
Metal Brake Washer
Flat Washer
Brake Washer
Hub
Keyed Washer
Spring
Cap Screw
Retaining Ring
Replace broken or worn parts and
slide parts onto shaft as shown.
Adjust hub tension and thread
welding wire. Close and latch door.
1
Close gun pressure roll assembly
and reinstall gun cover.
2
5
3
6
4
2
7
Tools Needed:
8
7/16 in
805 351-A / Ref. 143 223-A
8-3. Diagnostics
The following error messages are shown on the upper and lower displays to indicate specific errors. Explanations are in the text below:
TRIG
ERR
Indicates a trigger error. A trigger error occurs if the user has the trigger held for more than two
minutes without striking an arc. This error also occurs if the trigger is held when the feeder is powered
up. The error may be cleared by releasing the trigger.
JOG
ERR
Indicates a jog switch error. A jog switch error occurs if the user has the jog switch held for more than
two minutes. This error also occurs if the jog switch is held when the feeder is powered up. The error
may be cleared by releasing the jog switch.
PURG
ERR
Indicates a purge switch error. A purge switch error occurs if the user has the purge switch held for
more than one minute. This error also occurs if the purge switch is held when the feeder is powered
up. The error may be cleared by releasing the purge switch.
COOL
ERR
Indicates a water flow switch error. A water flow switch error occurs if no water flow is detected while
the trigger is pressed. Jog and purge switches will behave normally even if no water flow is detected.
Dip switch 2 on the motor control pcb must be set to enable this error. The error is cleared when water flow is detected or when the error is disabled.
TEST
ERR.1
Indicates a power on self diagnostic test error. The number provides information regarding the error.
If this error occurs, contact a Factory Authorized Service Agent.
COMM
ERR
Indicates a serial communication error. A communication error occurs 2 seconds after a loss of communication between the motor control pcb and the front panel pcb.
G.CAL
ERR.1
Indicates a gun calibration wire restriction error. This error occurs if the detected wire speed during a
calibration is too slow. This error will not prevent the feeder from operating, but wire speed accuracy
may be compromised. See section 8-4.
G.CAL
ERR.2
Indicates a gun calibration wire slip error. This error occurs if the detected wire speed during a calibration is too fast. This error will not prevent the feeder from operating, but wire speed accuracy may be
compromised. See section 8-4.
1234
ERR.M
Indicates a motor control pcb error. If this error occurs, contact a Factory Authorized Service Agent.
1234
ERR.F
Indicates a front panel pcb error. If this error occurs, contact a Factory Authorized Service Agent.
OM-239 210 Page 29
8-4. Troubleshooting
!
Disconnect power before troubleshooting.
Trouble
Remedy
Pressing gun trigger does not energize Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5-3).
feeder. Shielding gas does not flow and
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
wire feeder does not feed.
Wire feeds, shielding gas flows, but Check to see if ground clamp or weld cable is connected.
welding wire is not energized.
Wire feeds erratically.
Verify proper wire size is selected (see Section 7-2).
Check drive roll pressure in wire feeder and gun (see Section 5-8).
Clean or replace drive rolls as necessary.
Check and replace liner if necessary.
Arc varies and welding wire is kinked Verify proper wire size is selected (see Section 7-2).
when feeding out gun.
No weld output; gun/feeder does not Check gun control cable connection on wire feeder front panel (see Section 5-3).
work.
Erratic weld output.
Tighten and clean all connections.
Replace contact tip.
Verify proper wire size is selected (see Section 7-2).
Check drive roll pressure in wire feeder and gun (see Section 5-8).
Check and replace liner if necessary.
Wire does not feed; burnback in contact Verify drive roll size is correct.
tip.
Check drive roll pressure in wire feeder and gun (see Section 5-8).
Check and replace liner if necessary.
Gun overheating
(water-cooled models).
Be sure coolant flow rate is at least 1 qt/min.
Motor does not run.
Check drive roll pressure in wire feeder and gun (see Section 5-8).
Corrosion buildup in gun decreasing coolant flow rate. Backflush coolant system, clean coolant system
filter, and clean fittings.
Check and replace liner if necessary.
Have Factory Authorized Service Agent check feeder.
Gun Calibration
G. Cal ERR.1
Straighten gun cable.
Check drive roll pressure in wire feeder and gun (see Section 5-8).
Verify proper wire size is selected (see Section 7-2).
Check and replace liner if necessary.
Have Factory Authorized Service Agent check tach feedback.
Gun Calibration
G. Cal ERR.2
Verify wire is fed thru contact tip.
Check drive roll pressure in wire feeder and gun (see Section 5-8).
Verify drive roll size is correct.
Have Factory Authorized Service Agent check tach feedback.
OM-239 210 Page 30
Notes
OM-239 210 Page 31
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For Wire Feeder
OM-239 210 Page 32
239 209-B
OM-239 210 Page 33
OM-239 210 Page 34
1
2
61
Figure 10-1. Main Assembly
51
50
8
9
47
10
46
11
48
45
49
55
12
56
13 14
44
57
15
43
58
42
60
59
41
40
39
38
17
18
16
37
36
26
27
35
21
20
19
34
25
22
23
28
24
29
30
31
33
32
28
not available unless listed.
52
54 − Figure 10-2
7
. Hardware is common and
53 − Figure 10-3
3
4
5
6
SECTION 10 − PARTS LIST
242 437-A
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
. . 1 . . . . . . . . . . . . . . 089 572
. . 2 . . . . . . . . . . . . . . 240 263
. . 3 . . . . . . . . . . . . . . 223 814
. . 4 . . . . . . . . . . . . . +169 085
. . 5 . . . . . . . . . . . . . . 208 015
. . 6 . . . . . . . . . . . . . . 058 427
. . 7 . . . . . . . . . . . . . . 057 745
. . 8 . . . . . . . . . . . . . . 605 518
. . 9 . . . . . . . . . . . . . . 602 233
. . 10 . . . . . . . . . . . . . . 057 543
. . 11 . . . . . . . . . . . . . . . 113 168
. . 12 . . . . . . . . . . . . . . 058 428
. . 13 . . . . . . . . . . . . . . 058 628
. . 14 . . . . . . . . . . . . . . 058 424
. . 15 . . . . . . . . . . . . . . 151 697
. . 16 . . . . . . . . . . . . . . . 112 198
. . 17 . . . . . . . . . . . . . . 057 357
. . 18 . . . . . . . . . . . . . . 010 494
. . 19 . . . . . S1 . . . . . . 111 997
. . 20 . . . . PC5 . . . . . 239 921
. . 21 . . . . . . . . . . . . . . 139 041
. . 22 . . . . . . . . . . . . . . 239 885
. . 23 . . . PLG12 . . . 141 162
. . 24 . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 163 520
. . 25 . . . . . . . . . . . . . . . 211 989
. . 26 . . . . . . . . . . . . . . 183 914
. . 27 . . . . . . . . . . . . . . 220 805
. . 28 . . . . . . . . . . . . . . 073 302
. . 29 . . . . . . . . . . . . . . . 113 161
. . 30 . . . . . . . . . . . . . . . 113 165
. . 31 . . . . . . . . . . . . . . 120 396
. . 32 . . . . MP1 . . . . . 163 304
. . 33 . . . . . . . . . . . . . . . 113 900
. . 34 . . . . GS1 . . . . . 228 036
. . 35 . . . . . . . . . . . . . . 149 332
. . 36 . . . . . . . . . . . . . . 176 357
. . 37 . . . . . . . . . . . . . . 200 814
. . . . . . . . . . . . . . . . . . . 134 834
. . 38 . . . . . . . . . . . . . . . 112 090
. . 39 . . . . PC1 . . . . . 237 812
. . 40 . . . . . . . . . . . . . . 154 408
. . 41 . . . . . . . . . . . . . . 223 343
. . 42 . . . . . . . . . . . . . . 105 567
. . 43 . . . . . . . . . . . . . . 030 170
. . 44 . . . . . . . . . . . . . +239 203
. . 45 . . . . . . . . . . . . . . 090 439
. . 46 . . . . . . . . . . . . . . 089 573
. . 47 . . . . . . . . . . . . . ♦173 259
. . 48 . . . . . . . . . . . . . ♦139 678
. . 49 . . . . PC3 . . . . . 239 926
. . 50 . . . . . . . . . . . . . ♦605 798
. . 51 . . . . . S2 . . . . . 200 295
. . 52 . . . . . . . . . . . . . . 239 940
. . 53 . . . . . . . . . . . . . . Fig 10-3
. . 54 . . . . . . . . . . . . . . Fig 10-2
. . 55 . . . . . . . . . . . . . . . 111 569
. . 56 . . . . . . . . . . . . . . 134 058
. . 57 . . . . . . . . . . . . . . 083 147
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Catch, Link-lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Label, Set−Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spring, Cprsn 2.305 Od X .090 Wire X 2.500 Pld . . . . . . . . . . . . . . . . . . . . 1
Bolt, Stl Tap Hexhd .250−20x1.250 Gr5 Pld Full Thd . . . . . . . . . . . . . . . . . 1
Washer, Flat Stl .250 Id X .875 Od X .062Thk . . . . . . . . . . . . . . . . . . . . . . . 1
Spring, Cprsn .845 Od X .091 Wire X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Fbr Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strip, Brake Surface Anti-turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Shroud, Spool Wire 12 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Snap-in Nyl .937 Id X 1.125Mtg Hole . . . . . . . . . . . . . . . . . . . . . . 2
Bushing, Snap-in Nyl 1.375 Id X 1.750Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
Switch, Rocker Spst 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Circuit Card Assy, 14 Pin Filter HF (ROHS) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Strain Relief .450/.709 Id X1.115 Mtg Hole . . . . . . . . . . . . . . . . . . 1
Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, Cable Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Port No 18−14 11/C Type Awm 2−14 9−18 Cndct . . . . . . . . . . . . . 11Ft
Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Blank, Snap−in Nyl 1.250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, 750−14 Nps 1.48Hex .41H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, Ball Rdl Sgl Row .669 X 1.378 X .39 . . . . . . . . . . . . . . . . . . . . . . . 2
Block, Bearing Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stand-Off, .250-20 X 1.000 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shaft, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Brake, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Block, Bearing Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Valve, 24VAC 1Way .750−14 Thd 2mm Orf 100PSI . . . . . . . . . . . . . . . . . . 1
Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . 4
Hose, Sae .187 Id X .410 Od X 21.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose Assy, Sae .187 Id X .410 Od X 17.000 W/Clamps . . . . . . . . . . . . . . 1
Hose, Sae .187 Id X .410 Od (Order By Ft) . . . . . . . . . . . . . . . . . . . 4Ft (1.2 m)
Ftg, Pipe Brs Elbow 1/8 Npt X 3/16 Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Circuit Card Assy, Motor Control W/Program . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Snap−in Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . . . . 1
Clip, Wire Stdf .40−.50 Bndl .156Hole .031−.078Thk . . . . . . . . . . . . . . . . . 3
Skid, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
Cabinet, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, Keeper Link−lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Insulator, Water Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fitting, Water (Supplied With Water-cooled Gun) . . . . . . . . . . . . . . . . . . . . 2
Circuit Card Assy, 10 Pin Filter HF (ROHS) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Shldr.168id 0.375odx.047T .246odx.030T Nyl . . . . . . . . . . . . . . . 8
Switch, Rocker Spdt 15A 12V (ON)−OFF−(ON) . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Insulating Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel, Front W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Motor & Wire Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Meter, Flow 6−60 Scfh Of CO2 Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stand−Off Support, PC Card .156 Dia W/P&L .375 . . . . . . . . . . . . . . . . . . . 2
Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . . 4
OM-239 210 Page 35
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Figure 10-1. Main Assembly (Continued)
. . 58
. . 59
. . 60
. . 61
..............
. . . REED . . . .
..............
..............
214 860
239 892
134 201
169 089
..
..
..
..
Nut, Ln Pg21 1.26Hex .14H Nickel Plated Brass . . . . . . . . . . . . . . . . . . . . .
Switch, Ground Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand−Off Support, PC Card .312/.375w/Post&Lock .43 . . . . . . . . . . . . . .
Door, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
8
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 194 146 KIT, Water Connection
*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.
See Figure 10-1
Item 54
. Hardware is common and
not available unless listed.
4
*1
8
10
9
11
12
13
7
14
6
2
3
15
5
4
17
16
18
19
20
21
22
23
24
34
25
18
26
27
33
32
31
30
29
28
242 493-A
Figure 10-2. Motor & Wire Drive
OM-239 210 Page 36
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Figure 10-2. Motor & Wire Drive (Figure 10-1 Item 54)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
. . . . . . . . . . . . . 239 208
. . . . . . . . . . . . . 124 778
. . . . . . . . . . . . . . 111 630
. . . . . . . . . . . . ♦194 118
. . . . . . . . . . . . . . 194 119
. . . . . . . . . . . . ♦195 591
. . . . . . . . . . . . . 151 828
. . . . . . . . . . . . . 090 416
. . . . . . . . . . . . . 191 826
. . . . . . . . . . . . . 189 714
. . . . . . . . . . . . ♦188 098
. . . . . . . . . . . . . 189 716
. . . . . . . . . . . . . 196 895
. . . . . . . . . . . . . 203 616
. . . . . . . . . . . . . 241 856
. . . . . . . . . . . . . 085 244
. . . . . . . . . . . . . 225 718
. . . . . . . . . . . . . 010 224
. . . . . . . . . . . . . 058 549
. . . . . . . . . . . . . 602 306
. . . . . . . . . . . . . 189 823
. . . . . . . . . . . . . 189 920
. . . . . . . . . . . . . 189 605
. . . . . . . . . . . . . 192 929
. . . . . . . . . . . . . 196 613
. . . . . . . . . . . . . 196 604
. . . . . . . . . . . . . 239 218
. . . . B1 . . . . . 239 220
. . . . . . . . . . . . . 239 221
. . . . . . . . . . . . . 217 934
. . . . . . . . . . . . . 239 222
. . . . . . . . . . . . . . 132 611
. . . . . . . . . . . . . 201 225
. . . . . . . . . . . . . . 113 169
. . . . . . . . . . . . . 604 612
. . . . . . . . . . . . . 144 172
. . Drive Assembly, Wire (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, T 2.000 Bar W/.312 - 18 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Screw, 010-32 X .25 Hexwhd-pln Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Drive Roll .030−.035 (Part Of Wire Guide Kit 195 212) . . . . . . . . . .
. . . . Kit, Drive Roll .047−.062 (Part Of Wire Guide Kit 195 210) . . . . . . . . . .
. . . . Kit, Drive Roll .062 (Part Of Wire Guide Kit 195 209) . . . . . . . . . . . . . . .
. . . . Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Screw, Mtg Idler Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Shlder .192 Id X .375 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Housing, Wire Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spring ,Cprsn .660 Od X .067 Wire X 1.750 . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cup, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Cupped .328 Id X .812 Od X 16 Ga X .125 Lip . . . . . . . . . . . . .
. . . . Fastener, Pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Spring Cs .187 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Guide, Wire Inlet 1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Spring Cs .125 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Gear Assy, Shaft/Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing Assy, Upper Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Wave .400id X .672od X .010 St Stl Lbs . . . . . . . . . . . . . . . . . .
. . . . Case, Gear Wire Drive (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Washer, Shldr .187 Id .343 Od X .045t .234 Od X .138t Nyl . . . . . . . .
. . Insulator, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Torque 24VAC 50/60HZ 7.0 OZ Torque W/Lugs W/Tach Extension
. . Housing, Tachometer Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, K40x 20 Pan Hd−Trx Stl Pld Pt Thread Forming . . . . . . . . . . . . . . .
. . Cover, Housing Tachometer Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Optical Encoder Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Digital Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Gear, Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set # 8−32x .12 Cup Pt Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
3
1
1
1
3
1
1
1
1
1
1
♦Part of 194 118, 194 119, or 195 591 Drive Roll Kits
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-239 210 Page 37
. Hardware is common and
not available unless listed.
8
7
6
5
4
See Figure 10-1
Item 53
3
1
2
242 491-A
Figure 10-3. Front Panel Assembly
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Figure 10-3. Front Panel Assembly (Figure 10-1 Item 53)
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
. . . . . . . . . . . . . . . . . . 213 134 . . .
. . . . . . . . . . . . . . . . . . 231 469 . . .
.............................
. . . . . . . . . . . . . . . . . . 239 217 . . .
. . . . . . . . . . . . . . . . . . 231 470 . . .
. . . . . . . . . . . . . . . . . . 190 512 . . .
. . . . PC2 . . . . . . . . 237 824 . . .
. . . . . . . . . . . . . . . . . . 072 785 . . .
Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . .
Nut, 500−28 .69Hex .28H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . .
Nameplate, (Order By Model And Serial Number) . . . . . . . . . . . . . . .
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Adapter Encoder Shaft Mtg 375−32 To 500−28 . . . . . . . . . . . . .
Stand−off, No 6−32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . .
Circuit Card Assy, User Interface W/Program . . . . . . . . . . . . . . . . . . .
Screw, 006−32x .37 Hexwhd−Pln Stl Pld Slffmg Tap−Rw . . . . . . . . .
2
2
1
1
2
4
1
8
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-239 210 Page 38
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
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
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 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 2009−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2009 Miller Electric Mfg. Co.
2009−01
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising