Miller CONTINUUM DUAL WIRE FEEDER CE AND NON CE Manual

OM-277151J
2024-02
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P) Welding
Flux Cored (FCAW) Welding
Description
Continuum Dual
Feeder
CE And Non-CE Models
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
OWNER’S MANUAL
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.
From Miller t
Working as hard as you do −
every power source from
Miller is backed by the most
hassle-free warranty in the
business.
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, and our extensive service network is there to help fix the problem.
Warranty and maintenance information for your 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.
Miller is the first welding
equipment manufacturer in the
U. S. A. to be registered to the
ISO 9001 Quality System
Standard.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1
Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2
Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3
Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4
California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5
Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6
EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1
Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2
Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3
Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . 8
2-4
Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-5
Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-6
Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-1
Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-2
Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1
Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2
Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-3
Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-5
Wire Type, And Wire Feed Speed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1
Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-2
Feeder Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-3
Mounting Hole Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4
Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-5
Connecting Weld Output Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-6
10–Pin Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-7
Control Cable Connections (CE Model). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-8
Control Cable Connections (Non CE Model). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-9
Shielding Gas And Cooler Connections (CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-10 Shielding Gas Connections (Non CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-11 Lower Front Panel Connections (CE Model). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-12 Lower Front Panel Connections (Non CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-13 14 Pin Plug Information For Connecting Push/Pull Gun To Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-14 Opening Top Cover Of Aluma Pro Plus Gunn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1
Wire Feeder User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2
Description Of Front Panel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-3
Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4
LCD Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-5
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-6
Logs Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-7
Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-8
Creating, Changing And Saving a Weld Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-9
Trigger Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-10 Weld Sequence Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-11
Feedback Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-12 System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-13 Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6-14 USB Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-1
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-2
User Interface Error Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-3
Error Code Troubleshooting Description And Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. LLC, 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s), Commission Regulation(s) and Standard(s).
Product/Apparatus Identification:
Product
Continuum Dual Feeder CE
Stock Number
301199010
Council Directives and Commission Regulations:
•
2014/35/EU Low voltage
•
2014/30/EU Electromagnetic compatibility
•
2011/65/EU and amendment 2015/863 Restriction of the use of certain hazardous substances in electrical
and electronic equipment
Standards:
•
EN IEC 60974-5:2019 Arc welding equipment – Part 5: Wire feeders
•
EN 60974-10:2014/A1:2015 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
•
EN IEC 63000:2018 – Technical documentation for the assessment of electrical and electronic products
with respect to the restriction of hazardous substances
Signatory:
June 10, 2021
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
275626B
DECLARATION OF CONFORMITY
For United Kingdom (UKCA marked) products.
MILLER Electric Mfg. LLC, 1635 West Spencer Street, Appleton, WI 54914 U.S.A. declares that
the product(s) identified in this declaration conform to the essential requirements and
provisions of the stated Regulation(s) and Standard(s).
Product/Apparatus Identification:
Product
Continuum Dual Feeder CE
Stock Number
301199010
Regulations:
•
•
•
S.I. 2016/1101 Electrical Equipment (Safety) Regulations 2016
S.I. 2016/1091 Electromagnetic Compatibility Regulations 2016
S.I. 2012/3032 Restriction of the Use of Certain Hazardous Substances in Electrical and
Electronic Equipment Regulations 2012
Standards:
•
•
•
EN IEC 60974-5:2019 Arc welding equipment – Part 5: Wire feeders
EN 60974-10:2014/A1:2015 Arc welding equipment – Part 10: Electromagnetic compatibility
requirements
EN IEC 63000:2018 Technical documentation for the assessment of electrical and electronic
products with respect to the restriction of hazardous substances
Signatory:
June 10, 2021
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.
1-1.
Symbol Usage
DANGER! – Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in
the text.
NOTICE – Indicates statements not related to personal injury.
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 these hazards.
� Indicates special instructions.
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 Principal Safety Standards. Read
and follow all Safety Standards.
Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined as
one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge,
training and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children,
away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
� Do not touch live electrical parts.
� Wear dry, hole-free insulating gloves and body protection.
� Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
� Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
� Do not store or use equipment in standing water.
� Use AC output ONLY if required for the welding process.
� If AC output is required, use remote output control if present on
unit.
� 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!
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).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
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.
When making input connections, attach proper grounding conductor first—double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring — replace immediately if damaged — bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
OM-277151 Page 1
HOT PARTS can burn.
� Do not touch hot parts bare handed.
� Allow cooling period before working on equipment.
� To handle hot parts, use proper tools and/or wear
heavy, insulated welding gloves and clothing to
prevent burns.
FLYING METAL OR DIRT can injure
eyes.
� Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool, they
can throw off slag.
� Wear approved safety glasses with side shields even under your
welding helmet.
FUMES AND GASES can be
hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
� Keep your head out of the fumes. Do not breathe the fumes.
� Ventilate the work area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
� If ventilation is poor, wear an approved air-supplied respirator.
� Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
� 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.
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.
� Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
� Do not weld where flying sparks can strike flammable material.
� Protect yourself and others from flying sparks and hot metal.
� Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
� Watch for fire, and keep a fire extinguisher nearby.
� Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
� Do not cut or weld on tire rims or wheels. Tires can explode if
heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
� Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 (see Safety Standards).
� Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
� 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.
� Do not use welder to thaw frozen pipes.
� Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
� 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.
� Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
� 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.
� Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
BUILDUP OF GAS can injure or kill.
� Shut off compressed gas supply when not in use.
� Always ventilate confined spaces or use approved
air-supplied respirator.
� After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
� Use only correct fuses or circuit breakers. Do not oversize or bypass them.
� Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
� Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
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.
� Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
� Wear approved safety glasses with side shields under your
helmet.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
� Wear approved ear protection if noise level is high.
ELECTRIC AND MAGNETIC FIELDS
(EMF) can affect Implanted Medical
Devices.
� Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
� Wearers of Pacemakers and other Implanted Medical Devices should keep away.
� Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
� 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.
OM-277151 Page 2
CYLINDERS can explode if
damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
� Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
� Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
� Keep cylinders away from any welding or other electrical circuits.
� Never drape a welding torch over a gas cylinder.
� Never allow a welding electrode to touch any cylinder.
1-3.
� Never weld on a pressurized cylinder—explosion will result.
� Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
� Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the
valve.
� Keep protective cap in place over valve except when cylinder is in
use or connected for use.
� Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
� Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
Additional Hazards For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
� Do not install or place unit on, over, or near combustible surfaces.
� Do not install unit near flammables.
� Do not overload building wiring — be sure power
supply system is properly sized, rated, and protected to handle
this unit.
FALLING EQUIPMENT can injure.
� Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
� Use correct procedures and equipment of adequate capacity to lift and support unit.
� If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
� Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
� Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94-110) when manually
lifting heavy parts or equipment.
OVERUSE can cause
OVERHEATING.
� Allow cooling period; follow rated duty cycle.
� Reduce current or reduce duty cycle before starting to weld again.
� Do not block or filter airflow to unit.
WELDING WIRE can injure.
� Do not press gun trigger until instructed to do so.
� Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
BATTERY EXPLOSION can injure.
� Do not use welder to charge batteries or jump start
vehicles unless it has a battery charging feature
designed for this purpose.
MOVING PARTS can injure.
� Keep away from moving parts such as fans.
� Keep all doors, panels, covers, and guards closed
and securely in place.
� Have only qualified persons remove doors, panels,
covers, or guards for maintenance and troubleshooting as
necessary.
� Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
� Read and follow all labels and the Owner’s Manual
carefully before installing, operating, or servicing
unit. Read the safety information at the beginning
of the manual and in each section.
� Use only genuine replacement parts from the manufacturer.
FLYING SPARKS can injure.
� Wear a face shield to protect eyes and face.
� Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
� Sparks can cause fires—keep flammables away.
STATIC (ESD) can damage PC
boards.
� Put on grounded wrist strap BEFORE handling
boards or parts.
� Use proper static-proof bags and boxes to store,
move, or ship PC boards.
MOVING PARTS can injure.
� Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and local codes.
H.F. RADIATION can cause
interference.
� High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
� 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 away from moving parts.
� Keep away from pinch points such as drive rolls.
� 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.
OM-277151 Page 3
ARC WELDING can cause
interference.
� Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such
as robots.
� Be sure all equipment in the welding area is electromagnetically
compatible.
1-4.
California Proposition 65 Warnings
WARNING – This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
1-5.
For more information, go to www.P65Warnings.ca.gov.
Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
1-6.
� 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.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement
on the Uses of TLVs and BEIs. Website: www.osha.gov.
Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH.
SOM 2024–01
EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting,
and induction heating operations) creates an EMF field around the
welding circuit. EMF fields can interfere with some medical implants,
e. g. pacemakers. Protective measures for persons wearing medical
implants have to be taken. For example, restrict access for passers
−by or conduct individual risk assessment for welders. All welders
should use the following procedures in order to minimize exposure to
EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-277151 Page 4
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures
is recommended.
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT
UTILISATION
Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1.
Symboles utilisés
DANGER! – Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les
dangers possibles sont montrés par les symboles joints
ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas peut
donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
AVIS – Indique des déclarations pas en relation avec des blessures
personnelles.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout
danger.
� Indique des instructions spécifiques.
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 ce symbole, prendre garde et suivre
les instructions afférentes pour éviter tout risque. Les
consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les Normes de sécurité
principales. Lire et suivre toutes les Normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession d’un diplôme reconnu, d’un certificat ou d’un statut
professionnel, ou qui, par une connaissance, une formation
et une expérience approfondies, a démontré avec succès sa
capacité à résoudre les problèmes liés à la tâche, le travail
ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et
plus particulièrement les enfants.
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.
� Ne pas toucher aux pièces électriques sous tension.
� Porter des gants isolants et des vêtements de protection secs et
sans trous.
� 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.
� Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
� Ne stockez pas et n’utilisez pas l’équipement dans de l’eau
stagnante.
� Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
� 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’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder
ou le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste
à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !
� 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).
� Brancher correctement la mise à la terre et utiliser cet appareil
conformément à son manuel d’utilisateur et aux codes nationaux,
provinciaux et municipaux.
� Toujours vérifier la mise à la terre — vérifier et assurez-vous que
le conducteur de mise à la terre du cordon d’alimentation est bien
raccordé à la borne de mise à la terre dans le boîtier de déconnexion ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.
� En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
� Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez-les contre les étincelles et les pièces métalliques
chaudes.
� Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé -,
le remplacer immédiatement s’il l’est -. Un fil dénudé peut entraîner la mort.
� L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
� Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
� Ne pas enrouler les câbles autour du corps.
� Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
� Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
� Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide
doublée.
� N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
OM-277151 Page 5
� Porter un harnais de sécurité si l’on doit travailler au-dessus du
sol.
� S’assurer que tous les panneaux et couvercles sont correctement
en place.
� Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.
� Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
� Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
� Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
� Ne pas toucher des parties chaudes à mains nues.
� Prévoir une période de refroidissement avant de
travailler à l’équipement.
� Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
� 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.
� Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
� Eloigner votre tête des fumées. Ne pas respirer les fumées.
� 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. Pour déterminer la bonne ventilation, il est recommandé de
procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
� Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
� Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
� 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.
� 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.
� 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 ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
� Fermer l’alimentation du gaz comprimé en cas de
non utilisation.
� Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
OM-277151 Page 6
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
� 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).
� Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
� 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.
� Porter une protection corporelle en cuir ou des vêtements ignifuges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés
tels que des réservoirs, tambours ou des conduites
peut provoquer leur éclatement. Des étincelles
peuvent être projetées de l’arc de soudure. La projection d’étincelles,
des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
� 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.
� Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.
� Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
� Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.
� Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
� Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
� Ne pas couper ou souder des jantes ou des roues. Les pneus peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées
peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les
normes de sécurité.
� Porter une protection corporelle en cuir ou des vêtements ignifuges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
� Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
� Une fois le travail achevé, assurez-vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
� Utiliser exclusivement des fusibles ou coupe-circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
� 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.
� Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
Le BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
� Porter des protections approuvées pour les oreilles
si le niveau sonore est trop élevé.
Les CHAMPS
ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants
médicaux.
� Les porteurs de stimulateurs cardiaques et autres
implants médicaux doivent rester à distance.
� Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
Si des BOUTEILLES sont
endommagées, elles pourront
exploser.
Des bouteilles de gaz comprimé 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.
� 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.
� 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.
� 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).
� Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
� Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
exemple).
� Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
� 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.
� Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
� Ne jamais placer une torche de soudage sur une bouteille à gaz.
� Ne jamais souder une bouteille pressurisée - risque d’explosion.
� Ne pas utiliser le poste de soudage pour dégeler des conduites
gelées.
� Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière lerégulateur lors
de l’ouverture de la vanne.
� En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
� Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
OM-277151 Page 7
� Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
2-3.
� 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.
Symboles de dangers supplémentaires en relation avec l’installation, le
fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
� Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables.
� Ne pas installer l’appareil à proximité de produits
inflammables
� Ne pas surcharger l’installation électrique – s’assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
� Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les organes de roulement,
les bouteilles de gaz ou tout autre accessoire.
� Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
� 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.
� Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
� Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94– 110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
� Laisser l’équipement refroidir ; respecter le facteur
de marche nominal.
� Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
� Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
� Porter un écran facial pour protéger le visage et
les yeux.
� 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.
� Les étincelles risquent de causer un incendie - éloigner toute substance inflammable.
LES CHARGES
ÉLECTROSTATIQUES peuvent
endommager les circuits imprimés.
� Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces.
� Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
OM-277151 Page 8
Les PIÈCES MOBILES peuvent
causer des blessures.
� Ne pas s’approcher des organes mobiles.
� Ne pas s’approcher des points de coincement tels
que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
� Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
� Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EXPLOSION DE LA BATTERIE peut
provoquer des blessures.
� Ne pas utiliser l’appareil de soudage pour charger
des batteries ou faire démarrer des véhicules à
l’aide de câbles de démarrage, sauf si l’appareil
dispose d’une fonctionnalité de charge de batterie destinée à cet
usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
� S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
� Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
� Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.
� Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.
LIRE LES INSTRUCTIONS.
� Lire et appliquer les instructions sur les étiquettes
et le Mode d’emploi avant l’installation, l’utilisation
ou l’entretien de l’appareil. Lire les informations de
sécurité au début du manuel et dans chaque
section.
� N’utiliser que des pièces de remplacement provenant du fabricant.
� Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.
� 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.
� Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner
l’installation.
� L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
� Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
� Effectuer régulièrement le contrôle et l’entretien de l’installation.
� Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
� 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.
2-4.
� 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.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www. csagroup.org.
2-6.
� 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).
Proposition californienne 65 Avertissements
AVERTISSEMENT – Ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
2-5.
� Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement
on the Uses of TLVs and BEIs. Website: www.osha.gov.
Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH.
SOM 2024–01
Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des
champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations
de chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux,
p. ex. les stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple,
des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM
provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir
ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
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-277151 Page 9
symbols are found only on CE products.
Some
Some symbols are found only on CE products.
3-1.
1-1.
1-1. Additional
Additional Safety
Safety Symbols
Symbols And
And Definitions
Definitions
1-1.
Additional
Safety
Symbols
And
Definitions
SECTION
3
–
DEFINITIONS
symbols are found
only
on CE products.
Warning!
Out! There are possible hazards as shown by the symbols.
Some
Some symbols are found
only onWatch
CE products.
Warning!
Out! There are possible hazards as shown by the symbols.
Some symbols are found
only onWatch
CE products.
During
During the
the first
first 50
50 hours
hours of
of operation
operation keep
keep welding
welding load
load above
abov
During
the
first
50
hours
of
operation
keep
welding
load
above
Additional Safety Symbol Definitions
amperes.
amperes. Do
Do not
not weld
weld below
below 200
200 amperes
amperes of
of output.
output.
amperes.
Do
not
weld
below
200
amperes
of
output.
Safe
� Some symbols are found only on CE products.Do not discard product (where applicable) with general waste.
Saf
Safe5
Safe
Safe5
Warning!
Watchproduct
Out! There
are applicable)
possible hazards
as shown
by the symbols.
Do not discard
(where
with general
waste.
Warning!
Watch Out!
There
are possible
hazards Equipment
as shown by
the symbols.
Reuse
or
recycle
Waste
Electrical
and
Electronic
(WEEE)
by
disposing
at
a
designated
collection
Warning!
Watch
Out!
There
possible
hazards
as shownatbyathe
Warning!
There
are possible
hazards
asare
shown
by
the
symbols.
Reuse
or Watch
recycleOut!
Waste
Electrical
and Electronic
Equipment
(WEEE)
by disposing
designated collection
facility.
symbols.
facility.
Safe
Saf
Contact your local recycling office or your local distributor for further information.
Safe
Contact your local recycling office or your local distributor for further information.
Saf
After
Safe
After the
the first
first 50
50 hours
hours of
of operation,
operation, change
change the
the engine
engine oil
oil and
and
After
the
first
50
hours
of
operation,
change
the
engine
oil
and
Do not discard product (where
with general
Do notapplicable)
discard product
(where waste.
applicable) with general waste.
Do not discard product (where
applicable)
with general
waste.
Reuse
or
recycle
Waste
Electrical
and
Electronic
Equipment
(WEEE)
Do notor
discard
product
applicable)
with general
waste.
Reuse
recycle
Waste(where
Electrical
and Electronic
Equipment
(WEEE)
by disposing
at a
designated collection
by
disposing
at
a
designated
collection
facility.by disposing at a designated collection
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE)
Safe5
Safe
facility.
Reuse
or
recycle
Waste
Electrical
and
Electronic
Equipment
(WEEE)
by
disposing
at
a
designated collection
Safe5
Contact your local recycling office or your local distributor for further
facility.
facility. your local recycling
Contact
office
or
your
local
distributor
for
further
information.
information.
Wear
dryyour
insulating
gloves.
Do
not or
touch
with bare
not wear wet or damaged gloves. Safe3
Contact
local recycling
office
yourelectrode
local distributor
for hand.
furtherDo
information.
Wear
dryyour
insulating
gloves. Do
notor
touch
with bare
not wear wet or damaged gloves. Safe
Contact
local recycling
office
yourelectrode
local distributor
for hand.
furtherDo
information.
Safe
Saf
Saf
Wear
Wear dry
dry insulating
insulating gloves.
gloves. Do
Do not
not wear
wear wet
wet or
or damaged
damaged gloves.
gloves.
Wear
dry
insulating
gloves.
Do
not
wear
wet
or
damaged
Wear
dry
insulating
gloves.
Do
not
touch
electrode
with
hand.electrode
Do not wear
damaged gloves.
Wear
dry
insulating
gloves.
Do bare
notgloves.
touch
withwet
bareorhand.
Wear dry insulating gloves.
Do wear
not touch
electrode
with
bare hand. Do not wear wet or damaged gloves.
Do
not
wet
or
damaged
gloves.
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Protect yourself from electric shock by insulating yourself from work and ground.
Protect yourself from electric shock by insulating yourself from work and ground.
Safe
Safe
Safe
Safe
Saf
Saf
Saf
Saf
Wear
insulating
gloves.
Do
not
electrode
(wire)
with
Do
Wear dry
dry
insulating
gloves.
Do
not touch
touch
electrode
(wire)from
with bare
bare hand.
hand.
Do not
not wear
wear wet
wet or
or damaged
damaged glove
glove
Wear
dry
insulating
not
touch
electrode
(wire)
with
bare
hand.
Do
not
wear
wet
or
damaged
glove
Protect
yourself
fromgloves.
electricDo
shock
by
insulating
yourself
work
and ground.
Protect yourself from electric
shock
by insulating
yourself
from
work and ground.
Protect
yourself
from electric
shock
by insulating
yourself from work
Protect yourself
yourself from
from electric
electric shock
shock by insulating yourself from work and ground.
Protect
and ground.by insulating yourself from work and ground.
Protect yourself from electric shock by insulating yourself from work and ground.
Safe
Safe
Safe
Safe
Saf
Saf
Safe
Saf
Protect yourself from electric shock by insulating yourself from work and ground.
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
Protect
Protect yourself
yourself from
from electric
electric shock
shock by
by insulating
insulating yourself
yourself from
from work
work and
and ground.
ground.
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
Protect
yourself
shock
by
insulating
yourself
from
work
and
ground.
Disconnect
inputfrom
plugelectric
orDisconnect
power
before
working
onpower
machine.
input
plug
or
before
working
on
machine.
Disconnect input plug or power before working on machine.
Disconnect input plug or power before working on machine.
Disconnect input plug or power before working on machine.
Disconnect
input plug
or power
before working on machine.
Keep
Keepyour
your head
head out
out of
of the
the fumes.
fumes.
Keep
your
head
out
of
the
fumes.
Keep
your head out of the fumes.
Keep your head out of the fumes.
Keep your head out of the fumes.
Keep your head out of the fumes.
Keep your head out of the fumes
Use
ventilation
local
exhaust
to
the
Keep
your head
out of or
the
fumes
Use forced
forced
ventilation
or
local
exhaust
to remove
remove
the fumes.
fumes.
Use
forced
ventilation
or local
exhaust to remove the fumes.
Use
forced
ventilation
or
local
exhaust
to
remove
the
fumes.
Keep your head out of the fumes
Keep your head out of the fumes
Keepforced
your head
out ofor
thelocal
fumes
Use
ventilation
exhaust to remove the fumes.
Use
fan
fumes.
Use ventilating
ventilating
fan to
to remove
remove
fumes.
forced
ventilation
orUse
local
exhaust to
the fumes.
ventilating
fanremove
to remove
fumes.
Use
ventilating
fan
to
remove
fumes.
Use forced ventilation or local exhaust to remove the fumes.
Use forced ventilation or local exhaust to remove the fumes.
ventilation or
or local
local exhaust
exhaust to
to remove
remove the
the fumes.
fumes.
Use forced
forced ventilation
Use
Use
ventilation
orKeep
localwelding.
exhaustDo
to remove
the
fumes.
flammables
away
from
welding.
Do not weld near flammables.
Keep
flammables
away
from
not
weld
near
flammables.
Keepforced
flammables
away
from
welding.
Do
not
weld
near
flammables.
away
from
welding.
Do
not
weld
near
flammables.
Keep
flammables
Safe
Saf
Safe
Safe
Saf
Safe
Saf
Saf
Safe
Saf
Saf
Saf
Safe
Safe
Saf
Safe
Safe
Saf
Saf
Saf
Safe6
Saf
Safe
Safe
Safe
Saf
Saf
Safe
Safe
Safe
Saf
Safe
Safe
Saf
Saf
Saf
Safe6
Safe
Safe
Use forced ventilation or local exhaust to remove the fumes.
Use forced ventilation or local exhaust to remove the fumes.
Use forced ventilation or local exhaust to remove the fumes.
Welding
fire
watchperson
Weldingsparks
sparks can
can cause
cause fires.
fires. Have
Have a
fire extinguisher
extinguisher nearby,
nearby, and
and have
have a
watchperson ready
ready to
to use
use it.
it.
can
cause
fires.
Have
aa fire
extinguisher
nearby,
and
have
aa watchperson
ready
to
use
it.
Welding
sparks
OM-277151 Page 10
Safe
Saf
Saf
Safe6
Safe
Safe
at job site. Double-check all connections, relinking board position, a
Keep your head out of the
fumes
Keep
flammables
away
from
welding.
notextinguisher
weld
near
flammables.
input
voltage
before
Welding
sparks can
cause
fires.
Have Do
a fire
nearby,
andapplying
have a power.
watchperson ready to use it.
Do not cut on drums or any closed containers.
Safe7 2017 04
Safe62 201
Safe14 2012
Safe96
Safe17 2012
201
Become
trained
read
thefires.
instructions
working
onnearby,
the
For
single
phase
operation,
insulate
and isolate
red conductor.
Welding
sparksaand
can
cause
Have
a before
fire
extinguisher
and
Welding sparks can cause
fires. or
Have
fire extinguisher
nearby,
and
have
a watchperson
ready
to use it.
machine
welding.
Include
extra
length
in
grounding
conductor
and
connect
Cutting sparks can cause
fires.
Have
a
fire
extinguisher
nearby,
and
have
a
watchperson
ready
to use it.grounding
have a watchperson ready to use it.
conductor first. Connect black, white, and red wires (L1, L2, L3) to
Do not grip material near cutting path.
line terminals.
Safe40 2012 05
Safe63 201
Safe15 2012
Safe182012
201
Safe97
Become trained and read the instructions before working on the
machine or cutting.
notclosed
weld on
drums or any closed containers.
Do not weld on drums orDo
any
containers.
Turn offunit
power
torch.Do not move unit where two wheels are at a different height and unit
Falling
canbefore
cause disassembling
injury and damage.
Safe41 2012 05
could tip avoid tipping. Be careful when moving unit over uneven surfaces.
Safe16 201
Safe19 201
Safe98 201
Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.
Do
not
cut
on
drums
or
any
closed
containers.
Writer:
If
necessary,
replace
the
wordequipment
“handle” with
“lift
eye’. procedures.
Do
not stack
racks.paint
Lift only
with
proper
correct
Do
over
(cover)
theor
label.
Doliftnot
paint overand
(cover)
the label.
Safe46 2012 05
Do not
not remove
use oneor
handle to
or remove
support
unit.
Every 100 hours, check and clean filter and check condition of hoses.
Moving
parts
can injure.
Do
notrolls
grip
material
cutting path.
Drive
can
injurenear
fingers.
Drive rolls can injure fingers.
Safe17 201
Safe20
Safe99 201
201
Safe31 2017
Safe51 2012 05
Safe18 201
201
Safe100
Safe32 201
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.
?
Always
green,disassembling
Or
green wire
withtorch.
yellow
stripe,
wire
grounding
terminal.
Turn off connect
power before
Welding
and
drive
parts
aretoatsupply
welding
voltage
operation
Safe54
2017
04 -objects away.
Welding
wire
and
driveand
parts
at welding
during
operation
keep during
hands
and
metal
Do not weld on drums or
any closed
containers.
Connect
black,
white,
redare
wires
(L1,
L2,voltage
L3)objects
to line
terminals.
keep
hands
and metal
away.
Safe64 2017 04
Safe19 2012
201
Safe101
Safe33 201
After the first 50 hours of operation, change the engine oil and filter.
Pinch points can injure. Become trained and read the instructions before working on the
Pinch(cover)
points
canlabel.
injure.
Do not remove or paint over
the
machine
or welding.
Safe55 2012
Consult rating label for input power requirements.
05
Safe65 2012 06
Wear hat and safety glasses. Use ear protection and button shirt colWear
hatwelding
and safety
glasses. correct
Use ear protection
andWear
button
shirt
Recycle.
lar. (wire)
Use
helmet
filter.
complete
Wear dry insulating gloves.
Do not touch electrode
with bare
hand.with
Do not wearshade
wet orofdamaged
gloves.
collar.
Use welding
helmet
correct
shade of filter. Wear
complete
body protection
made
fromwith
leather
or flame-resistant
clothing
(FRC).
body
Bodyprotection.
protection includes oil-free clothing such as leather gloves,
heavy shirt, cuffless trousers, high shoes, and a cap. Safe57 2017 04
Safe66 2012 06
Become trained and read the instructions and labels before working on machine.
Become trained and read the instructions before working on machine.
Become trained and read the instructions before working on the
Become trained and read the instructions before working on the mamachine or welding.
chine orpoints
welding.
Read Owner’s Manual and inside labels for connection
and procedures.
Safe102
Safe20 2012
201
Safe34 2012
Safe103 2012
Safe35 201
Safe104 2012
Connect Green Or Green/Yellow grounding conductor to ground terminal first.
Connect input conductors (L1, L2, L3) to line terminals.
Safe65 2012 06
Safe67 2012 06
Connect green or green/yellow grounding conductor to ground terminal.
?V
Safe36 201
jumper
links
shown
on inside
label to match input voltage at
Induction heating can cause injury or burns fromMove
hot items
such
as as
rings,
watches,
or parts.
job site. Include extra length in grounding conductor and connect
grounding conductor first. Connect line input conductors as shown on
Safe105 2012
Safe74
2012
07
Wear
and safetyjumper
glasses.
ear protection
and button shirt
inside label. Double-check
all hat
connections,
linkUse
positions,
and
input voltage before applying
collar. power.
Use welding helmet with correct shade of filter. Wear comple
3
body protection.
Safe68 2012 06
Connect input conductors (L1, L2 And L3) to line terminals.Safe38 201
Close door before turning
on unit.
Safe 106 2012
OM- and button
Wear
hat and safety glasses. Use ear protection
shirt
collar. Use welding helmet with correct shade of filter. Wear comple
body protection.
Safe69 2012 06
Safe39 201
Read the Owner’s Manual
beforetrained
working
onread
this machine.
Become
and
the instructions before working on the
machine or welding.
OM-277151 Page 11
Safe70 2012 06
Safe40 2012
Negative
3-2.
Engine Oil
Miscellaneous
Symbols And Definitions
Positive
Flux Cored Arc
Welding (FCAW)
Alternating
Current
(AC)
Amperage
Engine Stop
Gas Preflow
Protective Earth
(Ground)
Voltage
Run (Fast)
Gas Postflow
Air Filter
Hertz
Rated Welding
Current
Output
Direct
Current
(DC)
Engine
Start
Engine RPM
Circuit Breaker
Degree Of
Supplementary
Protection
Protector
On
Line Connection
Direct Current
(DC)
Increase
Percent
Wire Diameter
Fuel
Gas Input
Idle (Slow)
Input
Engine Choke
Temperature
Output
OM-279639 Page 14
Percent
Purge By Gas
OM-277151 Page 12
Engine
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
U0
U2
I2
X
Rated No−Load
Voltage (OCV)
Cold Jog (Inch) Towards
Workpiece
Conventional
Primary Voltage
Tungsten Inert
Gas (TIG) Lift Arc
Filter
Remote
Single
Phase
Wire
Type
Alternator
Arc
Control
Arc
Control
USB
Read Instructions
Push Button
Load Voltage
Pulse
Air Carbon Arc
Cutting (CAC-A)
242a Rated
Trigger
Hold On
Current
Done
Rotating Knob
And Push Button
Duty Cycle
Gas Type
Gas Metal Arc
Welding (GMAW)
Gun
Voltage Sense Input
SECTION 4 – SPECIFICATIONS
4-1.
Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2.
Software Licensing Agreement
The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at
https://www.millerwelds.com/eula and are incorporated by reference herein.
4-3.
Information About Default Weld Parameters And Settings
NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical
welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are
for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld
parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose.
4-4.
Specifications
Input Power
Welding
Power Source
Type
Wire Feed
Speed Range*
Wire Diameter
Range
Welding Circuit Rating
Overall Dimensions
Without Spool
Covers
Overall Dimensions
With Spool
Covers
Weight
Height: 13.94
in.
(354 mm)
Width: 17.78
in.
(452 mm)
Length:
27.59 in.(701
mm)
Height: 16.52
in.
(419 mm)
Width: 19.19
in.
(487 mm)
Length:
29.55 in.(750
mm
61.5 lb
(27.9 kg)
0.035 To 5/64
in.
(0.9 To 2 mm)
50 VDC
Continuum 350
Continuum 500
Standard:
50-1000 ipm
(1.27-25.4
mpm)
Max Spool
Capacity:
18 in. (457
mm)
72 Volts DC
500 Amperes,
100% Duty
Cycle
Max Spool
Weight:
60 lb (27 kg)
4-5.
Wire Type, And Wire Feed Speed Table
Wire Size
Solid Steel
Metalcore Steel
Flux Cored Steel
0.035 in.
(0.9 mm)
0.045 in.
(1.1/1.2 mm)
0.052 in.
(1.3/1.4 mm)
0.062 in.
(1.6 mm)
MIG:
MIG:
MIG:
MIG:
50 To 1000 ipm
50 To 1000 ipm
50 To 800 ipm
50 To 600 ipm
(1.27 To 25.40 mpm)
(1.27 To 25.40 mpm)
(1.27 To 20.32 mpm)
(1.27 To 15.24 mpm)
Accupulse:
Accupulse:
Accupulse:
Accupulse:
75 To 1000 ipm
50 To 1000 ipm
50 To 800 ipm
50 To 600 ipm
(1.91 To 25.40 mpm)
(1.27 To 25.40 mpm)
(1.27 To 20.32 mpm)
(1.27 To 15.24 mpm)
MIG:
MIG:
MIG:
50 To 1000 ipm
50 To 900 ipm
50 To 700 ipm
(1.27 To 25.40 mpm)
(1.27 To 22.86 mpm)
(1.27 To 17.78 mpm)
Accupulse:
Accupulse:
Accupulse:
N/A
N/A
50 To 800 ipm
50 To 700 ipm
50 To 600 ipm
(1.27 To 20.32 mpm)
(1.27 To 17.78 mpm)
(1.27 To 15.24 mpm)
MIG:
MIG:
MIG:
5/64 in.
(2.0 mm)
N/A
N/A
MIG:
200 To 900 ipm
200 To 900 ipm
150 To 800 ipm
100 To 400 ipm
(5.08 To 22.86 mpm)
(5.08 To 22.86 mpm)
(3.81 To 20.32 mpm)
(2.54 To 10.16 mpm)
OM-277151 Page 13
4-6.
Environmental Specifications
A. IP Rating
IP Rating
IP21S
This equipment is designed for indoor use and is not intended to be used or stored outside.
B. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
14 to 104°F (-10 to 40°C)
-4 to 131°F (-20 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
C. Information On Electromagnetic Compatibility (EMC)
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radiated disturbances.
/
D. China EEP Hazardous Substance Information
中国电器电子产品中有害物质的名称及含量
China EEP Hazardous Substance Information
部件名称
Component
Name
(如果适用)
(if applicable)
有害物质
Hazardous Substance
铅
Pb
汞
Hg
镉
Cd
六价铬
Cr6
多溴联苯
PBB
多溴二苯醚
PBDE
黄铜和铜部件
Brass and Copper Parts
X
O
O
O
O
O
耦合装置
Coupling Devices
X
O
O
O
O
O
开关装置
Switching
Devices
O
O
X
O
O
O
线缆和线缆配件
Cable and Cable
Accessories
X
O
O
O
O
O
电池
Batteries
X
+
Do not spra
Recycle or
Hot Parts c
ment.
O
O
O
O
O
本表格依据中国SJ/T 11364的规定编制.
This table is prepared in accordance with China SJ/T 11364.
Connect G
Connect inp
O:
表示该有害物质在该部件所有均质材料中的含量均在中国GB/T26572规定的限量要求以下.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表示该有害物质至少在该部件的某一均质材料中的含量超出中国GB/T26572规定的限量要求.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold
of China GB/T 26572.
器电子产品的环保使用期限依据中国SJ/Z11388的规定确定.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
Environmen
Wire
OM-277151 Page 14
Feed wire b
Warning! Watch Out! There are possible hazards as shown by the symbols.
E. EU Ecodesign Information
Safe1 2012
Do notapplicable)
discard product
(where waste.
applicable) with general waste.
Do not discard product (where
with general
or recycle
Waste Electrical
and
Electronic
Equipment
Reuse or recycle Waste Reuse
Electrical
and Electronic
Equipment
(WEEE)
by disposing
at a(WEEE)
designated collection
by disposing at a designated collection facility.
facility.
Contact your local recycling office or your local distributor for further
Contact your local recycling
office or your local distributor for further information.
information.
Safe37 2017
Critical raw materials possibly present in indicative amounts higher than 1 gram at component level
Printed circuit boards
Component
Critical Raw Material
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Baryte, Bismuth, Cobalt, Gallium, Germanium, Hafnium, Indium, Heavy Rare Earth, Light Rare
Earth, Niobium, Platinum Group Metals, Scandium, Silicon Metal, Tantalum, Vanadium
Plastic components
Antimony, Baryte
Safe2 2017
Electrical and electronic components
Antimony, Beryllium, Magnesium
Metal components
Beryllium, Cobalt, Magnesium, Tungsten, Vanadium
Cables and cable assemblies
Display panels
Borate,Protect
Antimony,
Baryte,
Beryllium,
Magnesium
yourself
from
electric shock
by insulating yourself from work and ground.
Gallium, Indium, Heavy Rare Earth, Light Rare Earth,Niobium, Platinum Group Metals, Scandium
Batteries
Fluorspar, Heavy Rare Earth, Light Rare Earth, Magnesium
Safe3 2017
Protect yourself from electric shock by insulating yourself from work and ground.
Safe4 2017
Disconnect input plug or power before working on machine.
Safe5 2017
Keep your head out of the fumes.
Safe6 2017
Keep your head out of the fumes
Safe7 2017
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012
Use forced ventilation or local exhaust to remove the fumes.
Safe9 2012
O
OM-277151 Page 15
3
2
2
3
1
5
SECTION 5 – INSTALLATION
1
5
4
5-1.
6
Selecting A Location
6
4
Do not put feeder where welding
wire hits cylinder.
Movement
Do not move or operate unit where
it could tip.
Special installation may be required where gasoline or volatile
liquids are present - see NEC Article 511 or CEC Section 20.
1
1 Hand Cart
2 Lifting Forks
Use cart or similar device to move unit.
2
If using lifting forks, extend forks beyond opposite side of unit.
3 Line Disconnect Device
Locate unit near correct input power supply.
Location And Airflow
3
loc_feeder/running gear 2018-08
OM-243 346 Page 10
18 in.
(460 mm)
18 in.
(460 mm)
OM-279248 Page 1
OM-277151 Page 16
5-2.
Feeder Location
1 Lifting Eye
1
When a feeder is installed on top of a power
source, the lift eye is inserted through slot in
the feeder base.
5-3.
Mounting Hole Location
Holes are designed for 3/8 in. hex head
bolts.
2.8 in. 2.8 in. 2.8 in. 2.8 in.
(71 mm) (71 mm) (71 mm) (71 mm)
3.975 in.
(101 mm)
7.95 in.
(202 mm)
Ref. 266419-B
OM-277151 Page 17
5-4.
Connection Diagram
3
4
5
2
6
10
11
9
1
7
8
Turn off power
connections.
1 Welding Power Source
2 Wire Feeder
3 Gas Cylinder
4 Gas Hose
5 Feeder Cable
OM-277151 Page 18
before
making
6 Electrode Cable
7 Work Cable
8 Volt Sense Lead
9 Welding Gun
10 Push/Pull Gun
11 Workpiece
Use of shielding gas is dependant on Wire
Type.
gas pressure not to exceed
� Shielding
100 psi (689 kPa).
5-5.
Connecting Weld Output Cable
Turn off power before connecting
control cables.
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
NGO’s
machine.
Ensure all connections are tight.
tools/
Terminal Connection
Do not place anything between weld cable
terminal and output terminal. Make sure that
allen_set
the surfaces of the weld cableflathead
terminal and
output terminal are clean.
allen_wrench
philips he
1 Positive Connection Terminal
2 Correct Weld Cable Connection For Single Cable
1
2
1
3 Correct Weld Cable Connection for 2/0
And Larger Double Cables
pliers
needlenose
4 Incorrect Weldknife
Cable Connection steelbrush
5 Weld Output Terminal
6 Weld Cable Terminal
7 Supplied Bolt
9
8 Supplied Washer
8
7
6
9 Supplied Nut
5
solderiron
workclamp
Remove suppliedheavy-duty
nut and bolt
from weld out-light-duty workclamp
stripcrimp
put terminal. Insert bolt through hole in weld
cable terminal and hole in weld output terminal. Screw nut onto bolt until weld cable terminal is tight against output terminal. Torque
to 27-33 ft lb (36.6-45 N·m).
NGO’s
tools/
3
9/16 in.
allen_wrench
5
allen_set
flathead
philips head
wrench
crescent wrench
torque screwdriver
9/16 in.
9
torque wrench
8
pliers
needlenose
6
socket wrench
gre
drill
7
knife
steelbrush
nutdriver
chippinghammer
handream
4
solderiron
stripcrimp
heavy-duty workclamp
torque screwdriver
torque wrench
strapwrench
light-duty workclamp
qtip (swab)
socket wrench
drill
airgun
wirecutter
vicegrip
greasegun
hammer
frontcutter
crimper
awl
feelergauge
filterwrenchOM-277151 Page 19
5-6.
10–Pin Receptacle Information
Socket
Socket Information
+50 Volts DC Common
A
+50 Volts DC Common
B
Voltage Sense
C
+50 Volts DC Power
D
+50 Volts DC Power
E
ENET Rx —
F
ENET Tx —
G
Drain
H
ENET Tx +
I
J
5-7.
ENET Rx +
Control Cable Connections (CE Model)
Turn off power before making
connections.
1
1 Welding Power Source (Rear View)
2
3
4
2 Power Source 10 Pin Receptacle
3 Wire Feeder (Rear View)
4 Wire Feeder 10 Pin Receptacle
OM-277151 Page 20
5-8.
Control Cable Connections (Non CE Model)
Turn off power before making
connections.
1
1 Welding Power Source (Rear View)
2
2 Power Source 10 Pin Receptacle
4
3
3 Wire Feeder 10 Pin Receptacle
4 Wire Feeder (Rear View)
5-9.
Shielding Gas And Cooler Connections (CE Model)
Turn off power before making
connections.
2
1 Right Hand Shielding Gas Fitting
2 Left Hand Shielding Gas Fitting
1
3 Water-In Quick Connect Fitting
4 Water-Out Quick Connect Fitting
Connect hose from shielding gas supply to
fitting on rear of feeder.
4
3
Ref. 301199010
OM-277151 Page 21
5-10. Shielding Gas Connections (Non CE Model)
Turn off power before making
connections.
1 Right Hand Shielding Gas Fitting
2 Left Hand Shielding Gas Fitting
Connect hose from shielding gas supply to
fitting on rear of feeder.
1
2
5-11. Lower Front Panel Connections (CE Model)
Turn off power before making
connections.
1 Left Hand
Receptacle
4
Socket
Gun
Trigger
2 Right Hand 4 Socket Gun Trigger
Receptacle
3 Left Hand 14 Socket Push/Pull Trigger
Receptacle
4 Left Hand Water-In Quick Connect Fitting
5 Left Hand Water-Out Quick Connect
Fitting
6 Right Hand Water-Out Quick Connect
Fitting
7 Right Hand Water-In Quick Connect
Fitting
a single water-cooled gun is used on
� Ifeither
side, connect water hoses between right hand Water-Out Quick
Connect fitting and Left Hand Water-In
Quick Connect fitting.
277152−C
1
OM-277151 Page 22
4
5
3
6
7
2
5-12. Lower Front Panel Connections (Non CE Model)
Turn off power before making
connections.
1 Left Hand
Receptacle
4
Socket
Gun
Trigger
2 Right Hand 4 Socket Gun Trigger
Receptacle
3 Left Hand 14 Socket Push/Pull Gun Trigger Receptacle
Connect gun trigger plug to appropriate receptacle on feeder.
259145-D
1
3
2
OM-277151 Page 23
5-13. 14 Pin Plug Information For Connecting Push/Pull Gun To Wire Feeder
Pin
Pin Information
Motor 0 to 24 volts DC with respect to pin 2
1
Motor Common
2
+5 volts DC Tachometer Power
3
Tachometer Ref.
4
Tachometer Signal
5
Trigger
6
Trigger
7
Wire Speed Ref. +5 volts DC
8
Wire Speed Com
9
Wire speed 0 to +5 volts DC with respect to pin 9
10
Gun sensing resistor with respect to pin 9
11
Not Used
12
Not Used
13
Not Used
14
OM-277151 Page 24
5-14. Opening Top Cover Of Aluma Pro Plus Gunn
1
1 Top Cover
Squeeze sides of cover and lift up as shown.
To close cover, pivot cover closed on gun,
and push cover down until cover locks tight.
OM-277151 Page 25
SECTION 6 – OPERATION
6-1.
Wire Feeder User Interface
1
10
13
12
18
14
15
16
8
17
2
9
11
20
4
7
6
3
19
Ref. 266 061-B
5
OM-277151 Page 26
6-2.
Description Of Front Panel Controls
1 Memory Display
The Memory display shows the active weld
program. The range is from 0001 to 9999.
2 Memory/Variable Adjustment Knob
Use this knob to select a program number or
increase/decrease the variable shown in the
Memory display.
3 Arc Control Button
The Arc Control button is process dependent. It allows user to change the variable that
appears on the Values/Parameters display,
such as inductance, DIG, RMD (ball size) or
trim. The range can be +/- depending on the
process.
4 Memory 1-8 Buttons And LEDs
Use these buttons to select a stored program from the weld program library data.
The LED will indicate which program is selected and active.
The Variables/Parameters display will show
weld program library summary data for the
selected program.
Pressing this knob acts as a Select/Save
button. Press the button to select options
available in the LCD display
6 Scroll Knob And Select/Save Button
Rotate this knob to scroll available options
or increase/decrease the variable shown in
the LCD display.
LED illuminates to show that the voltage
function is active.
7 Values/Parameters LCD Display
14 Synergic Mode Active Indicator
This display shows all values and parameters that have been selected using the Soft
Key buttons and the Scroll knob and Save/
Select button.
LED illuminates to show that a synergic weld
process is active.
15 Amperage Indicator
8 Amperage/Wire Feed Speed Display
This display shows amperage, or wire feed
speed depending on the process selected
9 Amperage/Wire Feed Speed/Material
Thickness Adjustment Knob
Use this knob to increase/decrease amperage, wire feed speed, or material thickness
depending on the process selection. These
values appear on the Amperage/Wire Feed
Speed/Material Thickness display.
LED illuminates to show that a SMAW,
GMAW or CAG process is selected. Values
appear on the Voltage/Arc Length/Inductance/Arc Adjust/RMD display.
16 Wire Feed Speed Indicator
LED illuminates to show that a GMAW or
GMAW-P weld process is selected. Values
appear on the Amperage/Wire Feed Speed/
Material Thickness display.
17 Material Thickness Indicator
10 Voltage/Arc Length/Inductance/Arc Adjust/RMD Display
This feature will be functional in a later software release.
This display shows voltage, arc length, inductance, arc adjust or RMD depending on
the process selected.
18 Output ON Indicator
11 Voltage/Arc Control Adjustment Knob
LED illuminates to show that open circuit
voltage is present at the weld output
terminals.
5 Soft Key Buttons
Use these buttons to navigate the menus
appearing in the LCD display (See Section
6-4)
13 Voltage Indicator
Use this knob to increase/decrease voltage
or arc length depending on the process selection. These values appear on the Voltage/Arc Length/Inductance/Arc Adjust/RMD
display.
19 USB Port
Use this port for all USB related functions.
(See Section 6-14 ).
12 Arc Length Indicator
20 Parameter Lock Indicator
LED illuminates to show that arc length function is active.
LED illuminates to show weld parameters
are locked and active.
OM-277151 Page 27
6-3.
Connection Diagram
9
7
8
1
11
Ref. 289975-A
6
2
10
5
3
12
4
Turn off power
connections.
before
making
1 Wire Feeder Cable
2 Positive (+) Weld Output Terminal
3 Negative (-) Weld Output Terminal
4 Work Cable
5 Workpiece
6 Welding Gun
OM-277151 Page 28
7 Wire Feeder
8 Gas Hose
9 Gas Cylinder
10 Welding Power Source
11 Electrode Cable
12 Volt Sense Lead (Optional)
Use of shielding gas is dependant on Wire
Type.
connection diagram illustrates
� The
DCEP (reverse polarity) suitable for all
wires except self-shielded FCAW. The
majority of self-shielded FCAW wires
require DCEN (straight polarity).
6-4.
LCD Home Screen
1 Directory Indicator
8
9
1
#!#
Displays the directory path of current screen.
#!#
2 Program Number
Displays the current weld program number.
!! $ $"
#
! 2
3
3 Program Information
Displays the process type, wire diameter,
wire type and alloy, and gas mixture assigned to the current weld program.
4 Setup Soft Key
#$
"
##$"
%"#
Press Setup soft key to enter the Setup
menu screen. Setup Menu screen allows
weld programs to be created or changed.
For more information see Section 6-5.
5 Logs Soft Key
4
5
Ref 266 061-A
6
7
Press Logs soft key to enter Logs menu
screen. For more information see Section 66.
6 Status Soft Key
Press Status soft key to enter the Status
menu screen. For more information see Section 6-7.
7 System Soft Key
Press System Soft Key to enter System
menu screen. System menu allows access
to System Reset, USB, and board software
revision functions. For more information see
Section 6-12.
8 Network Connection Indicator
Displays the type of network connection
being used.
9 Internet
Displayed when Insight Core is enabled.
OM-277151 Page 29
6-5.
Setup Menu
1 Directory Indicator
1
Displays the current directory path.
2
2 Menu Name
Displays the current menu name.
3 Scroll Knob and Select/Save Button
4
3
Rotate knob to change active option. Active
option will have black circle next to it while inactive options will be white. Press the knob
to select the active option.
4 Options
Load New Process- Add or make changes to
a weld program. See Section 6-8.
Trigger Configuration- Select and edit dual
schedule, trigger dual schedule, 4T, and trigger hold features. See Section 6-9.
5
Ref 266 061-A
Weld Sequence Configuration- Change different aspects of the weld sequence such as
preflow, start amperage, crater, and post
flow. See Section 6-10.
Feedback Configuration- Set voltage feedback method to stud sense or sense lead.
See Section 6-11.
5 Home Soft Key
Press Home soft key to return to Home
menu screen.
6-6.
Logs Menu
1 Directory Indicator
1
Displays the current directory path.
2
2 Menu Name
Displays the current menu name.
3 Scroll Knob and Select/Save Button
4
3
Rotate knob to change active option. Active
option will have black circle next to it while inactive options will be white. Press the knob
to select the active option.
4 Options
5
Error Log- Displays a list of the last errors
the unit has detected. Use the Scroll Knob to
scroll through the list. From the Error log
screen press the Home soft key to return to
the Home screen, or the Logs Soft key to return to the Logs Menu.
Ref 266 061-A
Boot Log- Displays the sequence and status
of events that occurred during the boot
process.
5 Home Soft Key
Press Home soft key to return to Home
menu screen.
OM-277151 Page 30
6-7.
Status Menu
1 Directory Indicator
1
Displays the current directory path.
2
2 Menu Name
Displays the current menu name.
3 Scroll Knob and Select/Save Button
4
3
Rotate knob to change active option. Active
option will have black circle next to it while inactive options will be white. Press the knob
to select the active option.
4 Options
Ref 266 061-A
5
Load Bank Mode- Used to calibrate meters
or test equipment when servicing.
Accu-Power Mode- Displays instantaneous
power on wire feed speed display in kilojoules per second to the nearest tenth, updated once per second while welding. After
the weld, instantaneous power is displayed
for approximately ten seconds before the
display changes back to wire feed speed. If
wire feed speed is adjusted during the weld
operation, the display will show wire feed
speed while being adjusted and will revert
back to instantaneous power after adjustment has been made.
To calculate weld heat input, multiply the instantaneous power by the arc time then divide by weld bead length, see equation.
Actual / Command- Values displayed while
welding can can be set to display either actual values or command values set by user.
5 Home Soft Key
Press Home soft key to return to Home
menu screen.
OM-277151 Page 31
6-8.
Creating, Changing And Saving a Weld Program
At the Home screen, using either the memory adjustment knob or memory buttons, select the program number to be used.
From the Home screen, press the Setup
softkey.
In the Setup menu rotate the scroll knob to
make Load New Process the active option.
Press the knob to select Load New Process.
Follow screen prompts.
Step 1- Select Wire Type
Step 2- Select Wire Alloy
Step 3- Select Wire Size
Step 4- Select Gas Mixture
Ref 266 061-A
Step 5- Select Process
After selecting process, the display will read
Process Loading. At 100% the program is
saved and ready to use.
OM-277151 Page 32
6-9.
Trigger Configuration
In the Setup menu, rotate the scroll knob to
make Trigger Configuration the active option.
Press the scroll knob to select Trigger
Configuration.
are paired in numerical or� Allderprograms
for dual schedule functions. Pro-
gram 1 and 2 are paired, program 3
and 4 are paired, etc.
Select desired trigger function using the
scroll knob.
Dual Schedule allows selecting between a
pair of programs while actively welding. The
programs are paired as 1/2, 3/4, 5/6, and 7/
8. This feature requires an external Dual
Schedule switch for the MIG gun.
Ref 266 061-A
Trigger Dual Schedule allows the operator
to select between a pair of weld programs by
using the gun trigger. In Trigger Dual Schedule mode, release and retrigger the MIG gun
trigger to cycle between a pair of preselected
weld programs while actively welding. The
programs are paired as 1/2, 3/4, 5/6, and 7/
8.
Trigger Program Schedule allows the operator to select weld programs by using the
gun trigger. In Trigger Program Select mode,
press and release the gun trigger to toggle
through each active program when the welding system is at idle. This allows the selection of up to eight preselected weld
programs.
4T allows the operator to select between
weld parameters and crater parameters using the gun trigger. Preflow and Crater are
automatically enabled when 4T is selected,
both Preflow and Crater are configurable in
the Weld Sequence Configuration menu. If
the gun trigger is released during welding,
the unit goes into Trigger Hold mode, then
pressing and holding the trigger again
causes the unit to stay in Crater until the trigger is released and Crater parameter times
out.
Trigger Hold allows the operator to feed
wire without continuously pressing the gun
trigger. Configurable in the Trigger Hold settings, after the arc is initiated and actively
welding for the Inactive time, release the trigger before the Delay time ends and the system continues to weld. To end the weld,
press and release the trigger.
OM-277151 Page 33
6-10. Weld Sequence Configuration
At the Home screen, use either the memory
adjustment knob or memory buttons to select
the program number to be changed.
From the Home screen, press the Setup
softkey.
In the Setup menu, rotate the scroll knob to
make Weld Sequence Configuration the active option. Press the scroll knob to select
Weld Sequence Configuration.
In the weld sequence configuration screen,
rotate the scroll knob to desired function.
Press the scroll knob to either enable or disable the function.
With the desired function active, press the
Edit softkey to change the functions corresponding parameters:
Preflow- Adjust the length of time gas flows
before weld begins.
Start- Adjust voltage, wirefeed speed, time
and inductance used for starting weld.
Start Ramp- Adjust the length of time weld
takes from start to weld parameters.
Weld- Adjust the voltage, wirefeed speed,
time, and inductance.
Weld
Crater Ramp- Adjust the length of time from
weld to crater parameters.
Crater
Time
Crater- Adjust the voltage, wirefeed speed,
time, and inductance for crater settings.
Retract
Time
Start
Time
Preflow
Time
Postflow
Time
Time
Retract- Set the speed and the amount of
time the wire retracts after weld.
Postflow- Adjust the amount of time gas
flows after the weld.
Preflow
Start
Trigger
Pressed
OM-277151 Page 34
Weld
Crater
Trigger
Released
Retract
Postflow Sequence
End
6-11. Feedback Configuration
1 Directory Indicator
1
2
3
Displays the current directory path.
2 Menu Name
Displays the current menu name.
3 Active Indicator
Displays the active feedback method.
4
5
4 Scroll Knob and Select/Save Button
Rotate knob to change active option. Active
option will have black circle next to it while inactive options will be white. Press the knob
to select the active option.
5 Options
Stud Sense- Current feedback measurement
is taken at the output studs of the welding
power source.
Ref 266 061-A
6
Sense Lead- Current feedback measurement is taken with a volt sense lead.
6 Home Soft Key
Press Home soft key to return to Home
menu screen.
6-12. System Menu
1 Directory Indicator
Displays the current directory path.
1
2
2 Menu Name
Displays the current menu name.
4
3 Scroll Knob and Select/Save Button
3
Rotate knob to change active option. Active
option will have black circle next to it while inactive options will be white. Press the knob
to select the active option.
4 Options
5
Factory Reset- Allows user to reset all values
to factory defaults (See Section 6-13.
Ref 266 061-A
USB Functions- Update software and load or
save weld programs with a USB (See Section 6-14.
System Software Revision- Displays the current software revision of the welding system.
Network Settings- Displays information
about the network connections such as IP
Address.
Machine Serial Number- Displays the serial
number of the unit.
5 Home Soft Key
Press Home soft key to return to Home
menu screen.
OM-277151 Page 35
6-13. Factory Reset
From the Home screen, press the System
softkey.
In the System menu rotate the scroll knob to
make Factory Reset the active option. Press
the knob to select Factory Reset.
At the Factory Reset screen rotate the scroll
knob to select Yes. Press the scroll knob to
perform a Factory Reset.
Display will return to the Home screen when
Factory Reset is complete.
Ref 266 061-A
6-14. USB Functions
From the Home screen, press the System
softkey.
In the System menu rotate the scroll knob to
make USB Functions the active option.
Press the knob to select USB Functions.
Options
Write to system- Use a USB key to update
unit software and weld programs.
Write to USB-
System Settings- Save user created weld
programs to a USB key. User settings can
then be loaded on other units, or restored on
the current unit.
Ref 266 061-A
License Key- Available in Insight Core enabled units. Save license key to USB when
registering Insight Core.
Diagnostic Files-Available in Insight Core enabled units. Save diagnostic files to be sent
back to Miller Service Representatives.
OM-277151 Page 36
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING
7-1.
Routine Maintenance
A complete Parts List is available at www.MillerWelds.com
omplete Parts List is available at www.MillerWelds.com
N6
SECTION 17
MAINTENANCE & TROUBLESHOOTING
Disconnect power before maintaining.
17-1. Routine Maintenance
often if used in severe conditions.
� Service equipment more
� = Check
◇ = Change
� = Clean
� = Replace
Replace
Cracked
Torch Body
Every 3
Months
A complete Parts List is available at www.MillerWelds.com
Every
3
Months
MAINTENANCE AND TROUBLESHOOTING
� Unreadable Labels
1/2 in.
(13 mm)
�Weld Terminals
��Weld Cords And Cables
Weld Terminals
FUEL
Repair Or Replace
Cracked Cables And
Cords
Clean
And
Tighten Weld
Connections
��Clean And Tighten Weld Connections
�Damaged Gas Hose
SLUDGE
Every 6
Months
� Inside Unit
� Drive Rolls
*To be done by Factory Authorized Service Agent.
Out Inside of Unit
OM-231242 Page 29
OM-249336 Page 1
OM-277151 Page 37
7-2.
User Interface Error Information
1
ERR
BTN
2
3
4
Ref. 266 061-B
5
1 LED Display Message
Displays a short message describing the error or where the error is occurring. Some
messages may represent multiple different
errors. For more specific error information
see the LCD Display Message.
2 Message Type
There are three types of messages that will
be displayed.
ERROR- The system has experienced a
fault that must be addressed before continuing use.
OM-277151 Page 38
MESSAGE- No fault has occurred, but
some action must be taken before resuming
use of the welding system. For instance, input power may need to be cycled after loading new software.
WARNING- There is something that should
be addressed before continuing. For instance, the volt sense lead connection has
been lost.
3 LCD Display Message
Provides more information about the message being displayed.
4 LCD Solution Message
Describes the action needed to clear the
message or fault being experienced.
5 Logs Soft Key
Pressing the Logs soft key will take the user
to the Logs Menu (See Section 6-6). From
the Logs Menu it is possible to access the
Error Log. The LCD Error Log Messages are
stored in the Error Log.
7-3.
Error Code Troubleshooting Description And Tables
Red LED
Display
LCD Display
Message
BOOT ERROR or
BOOT FAIL
System Booting
Status bar
stopped at 1%,
2%, 3%, or 4%
Description
One of the components in the
system is not connected to the
network or the rest of the system.
Possible Causes
Wires in the interconnecting cable are disconnected.
There is a pin or socket in one of
the communication receptacles
that is broken.
Internal circuit board failure.
No Display
LCD is blank
Feeder is not powering up, white
power light is illuminated and
power source contactor is
energized.
Bad communication cable
Internal circuit board failure.
Possible Solutions
Replace the interconnecting cable
from the power source to the wire
feeder, or between the ROI and
wire drive, if it is a Swingarc
system.
Replace the power source, ROI,
wire drive, or wire feeder to have
serviced.
Replace the communication cable
between power source and wire
feeder.
Replace the power source, ROI,
wire drive, or wire feeder to have
serviced
ERR
THERM or
ERR OVERTEMP
ERROR
Thermal System
Problem
Welding Power
Source has
overheated
The power source is over
heating.
The fan louvers/wind tunnel
openings are blocked
The overtemp light is on
constant.
The fan motors are not turning on
or cannot rotate.
The heat sinks are dirty.
Cycle Power on
the Power
Source
The unit requires
a power cycle.
The power source must be serviced/repaired before proper
operation.
Blow out inside of wind tunnel per
the preventative maintenance
section.
Allow unit to cool
CYCLE
POWER
Ensure that there is a minimum of
18 inches distance between
power source and other objects.
This message may display if the
settings changed in the configuration of the system.
Cycle power on the power source
Cycle power on
power source
ERR
COMMS
ERROR
User Interface is not connected
to the rest of the system.
System Communication loss
Bad communication cable between the feeder and power
source.
Replace interconnecting cable.
Poor connection in the communication cable between the wire
feeder and the power source.
Replace the communication
cable.
Cycle power on
the power source
ERR
COMMS
ERROR
Internal comms
loss:
There are many communication
errors in the system indicating
where the problem may be. The
communication could be lost
from the power source, wire
feeder, ROI, or wire drive. The
detailed message in the LCD
screen will give the proper details
for the servicing technician.
Open connection in the interconnecting cable on the back of the
power source, wire feeder, ROI,
or wire drive.
Database in the system may be
corrupted.
ERR
WIRSTUK
ERROR
Wire stuck to work piece at the
end of the weld.
The power source, ROI, wire
drive, or wire feeder must be serviced/repaired before proper
operation.
Reinstall the system software.
.Break/Cut away from the work
piece.
Wire Stuck Error
Wire stuck to
workpiece at the
end of the weld
OM-277151 Page 39
Red LED
Display
LCD Display
Message
ERR ARC
ERROR
Arc error
occurred.
Description
The arc produced was not a valid
arc, weld voltage was too high or
too low for the parameters set on
the User Interface.
Possible Causes
Broken or disconnected weld
cable.
Wire delivery is too slow, arc
length too long.
Check wire
feeder and power
source.
ERR TRG
STUK
ERROR
Trigger held during power up.
Possible Solutions
Repair or replace weld cable.
Repair or replace work clamp or
cable connection.
Check/Replace gun liner.
Check drive roll pressure is properly set for the application.
Trigger Stuck error occurs if the
trigger is held when the feeder is
powered up. The error may be
cleared by releasing the trigger.
Trigger or trigger wires in the
MIG gun may be shorted
together.
The software in another component in the system is creating a
software mismatch.
A component in the system is
newer than the rest of the
components.
The software in the wire feeder
and power source are at different
revisions.
A different wire feeder and power
source were placed together for
the first time.
The system is experiencing a single phase condition, missing a
primary leg.
There is a poor connection in the
three phase plug or disconnect.
Repair or replace the MIG gun.
Release trigger
and press button
to clear error.
WRN SOFTWARE
WARNING
Incompatible software detected.
Sys SW Rev Mismatch Error
ERR INPUT
PWR
ERROR
Must use three
phase primary
power.
ERR INPUT
PWR
ERROR
Update system software
Contact a qualified electrician to
verify the primary power and possible solutions.
There is an open fuse or circuit
breaker.
Customer supplied primary voltage is too high.
Contact a qualified electrician to
verify the primary power and possible solutions.
The primary input
voltage is too
high.
Check the primary
connections.
ERR INPUT
PWR
ERROR
Customer supplied primary voltage is too low.
Poor connection in the three
phase plug or disconnect.
The primary input
voltage is too low.
Contact a qualified electrician to
verify the primary power and possible solutions.
Check the primary
connections.
ERR BTN
STUK
ERROR
Button on UI was held too long.
Button on UI
stuck
Membrane button on the overlay
is damaged.
The wire feeder or ROI must be
serviced/repaired before proper
operation.
Make sure all buttons are clear.
ERR ARC
STRT
ERROR
The weld output was active too
long before striking an arc.
Trigger held too
long without arc.
The drive rolls were open and the
wire did not move.
Ensure proper drive roll pressure
is applied.
There is no weld cable between
the feeder and power source.
Ensure the lower drive roll carrier
support plate is installed.
Install weld cable.
ERR REL
TRIG
ERROR
Trigger was held
too long.
Release trigger
and press button
to clear error.
OM-277151 Page 40
Release Trigger error occurs if
the user has the trigger held for
more than two minutes without
striking an arc or if the user holds
the trigger past the postflow
phase in a timed weld.
This may also happen if the Jog
button is depressed too long.
The trigger in the MIG gun is
shorted or stuck in a closed
position.
Repair or replace the MIG gun.
Red LED
Display
WRN
OVERAVER
LCD Display
Message
WARNING
Duty cycle
exceeded
System will be
ready to weld
shortly.
ERR AUX
PWR
ERROR
Description
The duty cycle of the power
source has been exceeded.
Possible Causes
The welding output was too high
for too long of a period of time.
Allow the welder to be powered
on and sitting idle until the error
clears, typically for a period of 15
minutes.
A device plugged into the 115
VAC receptacle is too much load.
Remove the device from the 115
VAC receptacle.
Auxiliary Power failure
The power source must be serviced/repaired before proper
operation.
The fans are not turning on.
Check the fan output from the
Control Power Supply board
(PC13).
The power source shut down to
allow itself to cool down.
The error will be active for a period of time.
The 115 VAC aux power circuit
board is experiencing a problem.
Aux power
problem
Cycle power on
the power
source.
ERR
THERM
ERROR
Thermal System
Problem
Cycle power on
the power
source.
ERR PWR
SRC
ERROR
Boost CS1, CS2,
CS3, or CS4 current error
Possible Solutions
The system is experiencing overheating on the primary or secondary heat sinks.
Also see ERR THERM 1,2, or 3
messages.
Primary current transducer sensor feedback is reporting too high
or too low amperage draw of the
input primary power.
The fan enable signal from the
Arc Control board (PC4) is not
present.
Ensure the Fan Enable wires are
terminated properly. Replace
(PC4)
Primary AC input may be too
high or too low on one or more
legs.
Contact a qualified electrician to
verify the primary power and possible solutions.
The feedback configuration setting is configured for V-Sense
and the cable is broken or
disconnected.
Replace the Volt Sense lead..
Cycle power on
power source.
WRN VSNS
LOS
WARNING
V-sense Feedback Warning
The power source is not receiving the voltage feedback input
from the internal connections or
the external volt sense lead.
Inspect the volt sense lead for
breaks.
Lost volt sense
lead feedback.
Replace the Volt Sense lead.
Replace the Interconnecting
cable.
The interconnecting cable has an
open wire carrying the voltage
feedback input.
ERR COOL
ERROR
TEMP
Cooler Over
Temperature
The temperature sensor in the
cooler is reporting the coolant
temperature is too high and shuts
down the system until the temperature is low enough.
ERR COOL
ERROR
The coolant lines do not have
coolant flowing.
FLOW
Cooler Low Flow
There is blockage in the torch or
in the torch coolant line.
Replace the torch or clear the
blockage in the cooler lines.
The welding application is exceeding the cooler capabilities.
Reduce the welding output.
The air in the coolant lines have
not yet been purged.
Turn on the weld output by Load
Bank mode several times and
clear the error each time until the
coolant gets into the flow indicator
and activates the flow switch.
The filter is clogged with debris.
There is blockage in the torch or
the torch coolant line.
Follow the coolant maintenance
instructions in the Cooler OM.
Replace the torch or clear the
blockage in the coolant lines.
OM-277151 Page 41
7-4.
Troubleshooting
Trouble
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Electrode wire feeding stops or feeds
erratically during welding.
Remedy
Check and secure weld cable connections.
Check welding gun trigger and connection. See gun Owner’s Manual.
Change to correct size drive roll.
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See welding gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger connection at wire feeder.
Unit completely inoperative — no
display
Check ArcConnect cable connection at wire feeder and power source.
Wire feeds when Jog switch is
pressed but not when gun trigger is
pressed.
Check welding gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See
gun Owner’s Manual.
Wire does not feed until trigger is
pressed but continues to feed after
trigger is released. Wire feeds as soon
as power is applied
Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas does not flow; wire feeds.
Check gas supply.
Check welding gun trigger leads and trigger switch. See welding gun Owner’s Manual.
Check supplementary protector at power source. See welding power source Owner’s Manual.
Check gas flowmeter.
Check gas hose for damage or loose connections.
Check for blockage in welding gun.
Erratic or improper weld output.
Use proper size and type of weld cable.
Clean and tighten all weld connections.
Check for correct polarity or welding circuit.
If using weld voltage sense lead, verify cable and connections. Repair or replace as needed.
� Do not leave unused lead connected to the weld voltage sense terminal.
OM-277151 Page 42
Notes
SECTION 8 – ELECTRICAL DIAGRAMS
Figure 8-1. Circuit Diagram
OM-277151 Page 44
274365-C
OM-277151 Page 45
Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Serial/Style Number
(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 Protective Equipment (PPE)
Service and Repair Replacement Parts
Training (Schools, Videos, Books)
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.
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS – PRINTED IN USA
© Miller Electric Mfg. LLC 2024-02