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Miller Electric XMT 304 CC/CV User's Manual

1. 1 27 RC10 166 679 Connector amp Sockets 1 28 TA sat 195 829 Transformer Control 200 400VAC 1 AE DO Meu 183 549 Bracket Mtg Aux Transformer 1 EE EE ET 207 727 Windtunnel 1 EE EE N 153 403 Bushing Snap In Nyl 750 Id X 1 000Mtg 2 ERE xus RR 177 547 Bushing Snap In Nyl 1 125Mtg 1 to eder ah QT zu 175199 Transformer Current 1 MERC MEET 025248 Stand Off 2 ve SD ass C1 us 188 446 Capacitor Polyp Film 5Uf 900VDC 1 dais C344 192 935 Capacitor Elctit 2700Uf 450VDO 2 mee OF eus PC2 233 042 Circuit Card Assy Interconnecting W Cmpnts 1 REC ATE ME PLG13 131204 Connector amp Sockets 1 EE PLG14 21 115093 Connector amp Sockets 2 AUOD Igea xus 182108 Choke Common Mode 1 AO IERE maka 17521407 Bracket pp eb ela Ela ss 1 AD RS EN
2. 27 6 4 Tro bleshootihg educere bert Hake Rie er EN Gna 28 SECTION 7 ELECTRICAL 29 SECTION 8 PARTS LIST 7 lle e ne ee xx rec ERU PEE GE ER ee Ee Ee Ee lee ed sa 30 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity For European Community CE Products This information is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 Declares that the product 304 European Contact Signature conforms to the following Directives and Standards Directives Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 December 1995 Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1989 Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 664 1
3. Ground hi Constant Current Constant Voltage Foot Control Line Connection Shielded Metal Arc Gas Metal Arc Three Phase Static Frequency Con AN Welding SMAW Welding GMAW venei Transformer Rectifier Rated No Load U Conventional X U 0 Voltage Average 1 Primary Voltage Load Voltage Duty Cycle Degree Of Rated Welding H Z Heriz Protection Current Percent Lift Arc Trigger 4 Pulsed Da Hold Operation Single Phase 3 Three Phase GTAW Rated Maximum Maximum Effective iiic IF Lift Arc Operation imax Supply Current 1eff Supply Current crease GTAW OM 233 045 Page 14 SECTION 4 INSTALLATION 4 1 Specifications Amperes Input Maximum at Rated Load Rated Welding Voltage Amperage Ss Output Range Range dr Rating Output 50 60 Hz 400 V KVA KW 300A 32 Volts DC 10 35 5 400 90 23 6 159 0 0 od 6096 Duty Cycle i While idling 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min 500 utes that unit can weld at rated load 400 without overheating n If unit overheats output stops a 05 300 Help message is displayed see Section 6 3 and cooling fan runs X 225 Wait fifteen minutes for unit to cool 9 200 Reduce amperage or duty cycle be fo
4. a mn te RE OE OO OE AO oe PE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 SymbolesuitiliSeS es ss ME RA late E be AE RE Se er E Lie 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Information EER b ee Led eke Oe u ERE EE E 9 SECTIONS DEFINITIONS 1 EE ERROR RS dm GE ed ROES mien ER ER EC x 11 3 1 Manufacturers Warning Label Definitions 11 3 2 Manufacturers Rating Label 13 3 3 WEEE Label 2 is eel ike tate Soke aie tahoe au Un EM eM eie 13 3 4 Symbols And Definitions ee 48 cepe ar e ER eer GEE e Mein STR QURE E ER 14 SECTION 4 INSTALLATION 2 EG Ee me tees cae seeds FE GEMENS EE ee 15 4 1 Specifications EO EA EE RR EE 15 4 2 Duty Cycle And Overheating 15 43 VoltAmpeie GUurveSr vr ere ER EG ue a
5. OM 233 045C 2007 10 m Miler je Multiprocess Welding Description E3 Da 23 Arc Welding Power Source XMT 304 CC CV C 400 Volt Models RoHS OWNER S MANUAL File MULTIPROCESS egg Pd Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U E Bl PEENI 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 Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years 90 00012000 of reliable servi
6. Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr guence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque
7. 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit gt Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil gt Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la Sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropr
8. HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry st
9. Nut Conduit 1 000 Npt Knurled 1 CB1 161 078 Circuit Breaker Man Reset 1P 7 250VAC 1 vides 2 083 432 Circuit Breaker Man Reset 1P 10A 250VAC 1 ed RE EE N 175147 Panel REAM rv ra DR CR RAE pr Ee rr 1 ttes 213099 Bushing Strain Relief 1 TIT ICM 178563 Nut Nylon 1 000 Npt 1 Xn esL e tU EK 186 439 Ftg Bushing b nr eg RES d sg EE N ED 210 346 Cable 6mm 4 C 60 1 MR EE Plate Ident Rear Order By Model And Serial Number 1 m 217 297 Cover Receptacle Weatherproof Duplex Rept 1 uu etude iesus us 175188 BOX os EE oe ee drew Exe rcg tete ate e GE eR 2 up ci ED ET 192 853 Bracket Mtg Contactor Capacitor PC Board 1 C ND PET EES 229 959 Circuit Card Assy Control 1 m N PLG2 131056 Connector amp Sockets 1 Vias asi PLG3 130203 Connector amp Sockets 1 PLG5 115091 Connector amp Sockets en PLG7 115093 Connector amp Sockets
10. ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de bles blind s l utilisation de filtres de ligne ou
11. 1992 dec coni 1 07 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2007 04 Protect yourself and others from injury read and follow these precautions 1 A 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 ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are a
12. 3 0 2 ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 ax 2 95 2x95 2 ea 2 0 2 ea 3 0 2 ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x95 2x95 2x120 2 ea 2 0 2 ea 3 0 2 ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x95 2x120 2x120 Output Receptacles 2 ea 2 0 2 ea 3 0 2ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 2 2 0 2ea 3 0 2ea 4 0 3 ea 3 0 3 ea 4 0 3 ea 4 0 600 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 233 045 Page 18 4 6 Remote 14 Receptacle Information ST 801 192 REMOTE 14 Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circuit breaker CB2 OUTPUT B Contact closure to A completes 24 volts ac con CONTACTOR tactor control circuit 115 VOLTS AC 115 volts ac
13. amp amp x SPX amp S M S al Sp al S y A A A A A A z ET AAA A A A A AA A ACA QUIS ee AER REI 1 T RC gt J gt 255 Rc2 5 5558884 8888299 I CONTACTOR x gcc 9 RC3 10 gt gt 24V 27 AK B PD tONIACIOR RC2 8 5 83 4 gt L lt lt 2 RC3 2 gt gt HE REF IN 30 2 LF K Rc2 11 DREIN X RC2 10 RC1 PLG1 RC6 1 gt gt 2 2 RC2 PLG2 RMT OUT 23 ee REARS RCS PLGS 57 gt Rc2 3 1 RC5 PLG5 RC6 2 gt gt 2 RCG PLES m RED SN POSITIVE gt 1V 1008 lt RC2 4 CONTROL BOARD 2 2 RC9 PLG19 p gt REF COM 0 Ww RC4 1 gt 2 gt gt BL OR js uS V 29 9 Le p x BE go an 1 1 1 1 1 1 6 lt lt RC2 2 E 8 8 8 9888 YYYY 84 22 V y y y y RC5 1 gt NEGATIVE 42 26 N cc cv 43 AARE A E M gt SELECT SRI RC5 2 gt CLEAR c9 BLACK 42 AED RCI WHT RC2 PLG11 ALK RC5 PLG18 For Welding Power Source ircuit Diagram Figure 7 1 C SECTION 8 PARTS LIST 801 605 H Figure 8 1 Parts Assembly OM 233 045 Page 30 Item Dia Par No Mkgs No Description Quantity Figure 8 1 Parts Assembly cu kuah cs 48 Wrapper eer seinen a a squa aris 1 OMIT 175256 Insulator Side EE RE ee REI OR EIE ane 2 EUN METER 195585 Handle er
14. la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les
15. qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 233 045 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les so
16. 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label 1 96 OM 233 045 Page 11 S S 179 190 A Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 60 seconds after power is turned off before working on unit OR Check input capacitor voltage and be sure it is near 0 before touching any parts 4 96 5 179 304 Warning Watch Out There are possible hazards as shown by the symbols When power is applied failed parts can explode or cause other parts to explode Flying pieces of parts can cause injury Always wear a face shield when servicing unit Alw
17. components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipmentto the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor
18. de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant 1 soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat r
19. eA RR EN Dea X Ren 1 DA EER 229 966 Circuit Card Assy Front Panel amp Display W Program 1 PLG11 115091 Connector amp Sockets 1 uus FM 175084 Fan Muffin 24VDC 3000 1 RC1 230 050 Receptacle W Leads amp Plug 1 ER OM AE TE 178 548 Terminal Connector Friction 2 AE DT C78 222488 Capacitor Assembly 2 ETE PH UR 185 732 unas AA GIN MOVIL 1 m EG 129 525 Receptacle Twlk Insul Fem 2 PTT CER 145 088 Kit Connection Dinse M EE ET Nameplate Order By Model And Serial Number 1 MUTET 070 590 Tubing GI Acryl 325 Order By Ft teet 174 992 Knob Pointer 840 2 wit EE ER 175 855 Boot ces esie e ONU cute pra PE e E Re TR 1 A SOS s t o DR 174991 Knob Pointer 1 250 2 wit O4 EE 176 226 Insulator Switch Power 1 LR OD etre is ST uus 231 19
20. equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit T OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit nn nn e d F N FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N 3 e Puton grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards 22 e MOVING PARTS can cause injury e
21. fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Enn L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement specter le cycle op ratoire nominal E e R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste KF LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les o circuits imprim s gt S 2 N e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent 9 provoquer des blessures 2 5 Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 233 045 Page 7 LES FILS DE SO
22. la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 233 045 Page 8 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com
23. present see NEC Article 511 or CEC Section 20 Location Appleton WI USA loc 2 3 96 ST 801 192 OM 233 045 Page 17 4 5 Weld Output Terminals And Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area gt Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding Weld Output Terminals A Turn off power before connecting to weld out put terminals 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30 or Less 45m 60m 70m 90m 105 m 120 m A Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 85 1 50 1 O 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 ee 2 35 1 60 1 0 60 2 0 70 3 0 95 4 0 120 268 20 26a 2 0 2x70 2x70 2 ea 2 0 2ea
24. 1 Switch 3Pst 600VAC Scr Term Wide 1 m m 179 310 Label Warning General Precautionary 2 edt us eat 199840 Bus Bar Diode 2 When ordering a component originally displaying a precautionary label the label should also be ordered BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 233 045 Page 32 Notes H OF WELDING TECHNOLOGY Start Your Professional 400 trade square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 Notes SOCKET WRENCH SELECTION TABLE DEEP SOCKET WRENCH SELECTION TABLE U S STANDARD METRIC Specifications Socket or Wrench Size Specifications Socket or Wrench Size 0 5 Dens eed ot Tm ESO dani 59 mat 1 4 in 250 in 3 8 in 7 16 in 6mm 2362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 6 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13 16 in 14 mm 5512 in 22mm 22 mm 9 16 in 5625 in 7 8 in 7 8 in 16 mm 6299 in 24 mm 24 mm 5 8 in 625 in 15 16
25. ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for
26. Control SMAW 85 Blank Preset Amps V A Panel Control DE Cus 80 0 85 Actual Volts OCV Preset Amps V A Voltage Sensing 6 Wirefeeder 80 0 Flashes OCV And Preset Blank OM 233 045 Page 23 5 3 Mode Switch Settings The SMAW modes provide the Adaptive Hot Start feature which automatically increases the output amperage at the start of a weld should the start require it This eliminates electrode sticking at arc start Mode Output Control Select or E Amp 0 Scratch Start TIG GTAW Weld O pu Tan Lift Arc Trigger Selen WE Hold TIG GTAW Requires Control TIG GTAW With Select 5 E Amp gt HF Unit Pulsing Device Or Remote Control Requires E Control Select 5 E Volt G MIG GMAW Requires E Feeder Pulsed MIG A GMAW P Select Volt Requires an external pulsing device Requires A Feeder or Control Select or E Amp lt NT Control SMAW Requires 7 Control 7 Panel Control se 9 SMAW Weld Select 5 E Volt Voltage Sensing Wirefeeder Requires E Feeder OM 233 045 Page 24 5 4 Lift Arc Trigger Hold TIG fu 1 2 Workpiece F gt Procedure requires Z control Start sequence Touch tungsten electrode to workpiece at weld start point Momentarily depress output Switch Slowly lift
27. Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire 53 STATIC ESD can damage PC boards lt MOVING PARTS can cause injury NU e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct
28. Protected by circuit breaker CB1 OUTPUT J Contact closure to completes 115 volts ac con CONTACTOR tactor control circuit C Output to remote control 0 to 10 volts dc 10 volts dc in MIG mode REMOTE OUTPUT D Remote control circuit common CONTROL E 010 10 volts dc input command signal from re mote control H Voltage feedback 1 volt dc per 10 output recep AN tacle volts AMPERAGE F Current feedback 1 volt dc per 100 amperes VOLTAGE M CC CV select G Circuit common for 24 and 115 volts ac circuits GND K Chassis common The remaining sockets are not used 4 7 110 Volt AC Duplex Receptacle amp 1 110V7A AC Receptacle Power is shared between duplex receptacle and Remote 14 recep tacle see Section 4 6 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects 110 volt ac portion of duplex receptacle and Remote 14 receptacle from overload CB2 protects 24 volt ac portion of Remote 14 receptacle from overload Press button to reset breaker Ref ST 801 245 A OM 233 045 Page 19 4 8 Electrical Service Guide NOTICE INCORRECT INPUT POWER can damage this welding power source This welding power source requires a CONTINUOUS supply of input power a
29. UDAGE peuvent provoquer des blessures Ne pas appuyer sur la g chette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures AJ e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipe
30. UVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions Les doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer
31. Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller
32. andards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND
33. aux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 233 045 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchau fement ou un incendie Avant de commencer le soudage v rifier e s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s Ne pas souder dans un endroit l ou des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du sou
34. ays wear long sleeves and button your collar when servicing unit After taking proper precautions as shown connect power to unit 4 96 Warning Watch Out There are possible hazards as shown by the symbols Falling equipment can cause injury and damage to unit Always lift and support unit using both handles Keep angle of lifting device less than 60 degrees Use a proper cart to move unit Do not use one handle to lift or support unit 1 96 OM 233 045 Page 12 3 2 Manufacturer s Rating Label 10 400A 26V 30A 21 2V 375A 35V 1 50A 16 5V 400A 34V ran 30 60 100 Fan 35 60 100 15 30 60 100 S EE EE BESEER EE EE pe 50 60 Hz Ref 235 855 A 3 3 WEEE Label Do not discard this product with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information OM 233 045 Page 13 3 4 Symbols And Definitions Alternating A Amperage Current V Voltage Output 2 Circuit Breaker Remote On Off Gas Ta Nte Negative lt Voltage Input Direct Current Positi Protective Earth DC
35. ce with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Ti Symbol stor vq ER ERA E e RE Raton VG UTE WE ts 1 1 2 Arc Welding Hazards rtt rre d puce Set 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 08 4 1 5 Principal Safety Standards 4 1 6 EME Information i
36. dage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS 4 1 voir les nor mes de s curit Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encasde non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev a
37. e examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 233 045 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada LAW 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Reg
38. e constitue un danger n Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante P gt Indique des instructions sp cifiques e Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MO
39. e open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual 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 SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Ed Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 233 045 Page 1 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 If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied resp
40. ear arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal 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 Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated
41. eek ah et 175 482 21 BE ea 2 EE u EE N 109 056 o e ra e PAD aU Glos Dedi an aca 2 42 SR1 179 629 Kit Diode Power Module 1 43 PM1 2 233 043 Kit Transistor IGBT Module 1 OM 233 045 Page 31 No Mkgs No Description Quantity Figure 8 1 Parts Assembly Continued 44 178570 StabilizeF mere etre e edel a pr ua aces 1 acd s oras E us 173 563 gt sais ease eH ed e M Rr E akuna 1 46 HOME RD Mr 207 725 Heat Sink Power Module 1 47 TT iss 179 616 Transformer sobre ER S RU pe LU wat etna 1 saa MO eu da dnd arra DA 207 467 Heat Sink ee re brote o dA oe Ae ans ea A 1 Sed 175255 Insulator Rectifier 1 ERA am Y AT CR LE 175 969 Insulator PC Catd 222 02 Ee EER anne aus a AR pa er 2 EE yma Mee as 181197 Gasket Di Dt Rubber 1 ra OD racist ED 229325 gt Foot MIQ Unit EDE mm aa ua GE XUI 4 wired ate TE 176 736 Screw 4 Lv GE 175 132 cbe Tupisa eu d
42. electrode An arc will 1 2 form when electrode is lifted Touch Seconds To stop welding momentarily depress output switch and out put will shut off Note If output switch is momen tarily depressed and tungsten is not touching workpiece Do not touch tungsten to work Output will shut off in 3 seconds Start sequence over Do NOT Strike Like A Match Ref S 156 279 OM 233 045 Page 25 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance ao A Disconnect power gt Maintain more often before maintaining during severe conditions 3 Months Replace Damaged Or Unreadable Labels Repair Or Replace Replace Cracked Cracked Torch Body Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections PE Blow Out Inside Z 6 2 Blowing Out Inside Of Unit A Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown ST 801 192 OM 233 045 Page 26 6 3 Voltmeter Ammeter Help Displays HE L 3 NHE L P 1 P 2 P 3 5 E 10 HE L F gt All directions are in reference to the front of the unit All circuitry referred to is lo cated inside the unit 1 Help 0 Display Ind
43. en the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements Notes OM 233 045 Page 20 4 9 Connecting 3 Phase Input Power Installation must meet all National and Local Codes have only quali fied persons make this installation Disconnectand lockout tagout in 3 put power before connecting input conductors from unit AA A Always connect green or green A yellow conductor to supply GND PE Earth Ground grounding terminal first and never to a line terminal For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Overcurrent Protection Select type and size of overcurrent protec tion using Section 4 8 fused disconnect switc
44. g i qo EY ep 16 4 4 Selecting A Location p era ee e a XO Ea UTOR qo AE 17 4 5 Weld Output Terminals And Selecting Cable 18 4 6 Remote 14 Receptacle 1 19 4 7 110 Volt AC Duplex Receptacle 19 4 8 Electrical Service 20 4 9 Connecting 3 Phase Input Power 21 SECTION 5 OPERATION EE Ge ERI ee ER GE Ee EE SEE EG aa ES equ 22 5 12 Front Panel Controls sig ER Ee DE en LOUP 22 5 2 Meter Functions soci pp E Robe Rb toe E RU RUE Ui 23 5 3 Mode SwitchiSettinigs EGG EG Re EERS EES RENE DE RU UR 24 5 4 Lif AreTrigder Hold TIG Re SS ag DE E EE ERR sl weds eae od ERE ES 25 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 26 6 1 2 INE ER IA Rs hiya 26 6 2 Blowing Out Inside 4 26 6 3 Voltmeter Ammeter Help Displays
45. h shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position Tools Needed ES R 2 04 Ref 802 136 A 801 192 OM 233 045 Page 21 SECTION 5 OPERATION 5 1 Front Panel Controls 1 Power On Off Switch Lx The fan motor is thermostatically controlled and only runs when cooling is needed Voltmeter see Section 5 2 Ammeter see Section 5 2 Voltage Amperage Adjustment Control Mode Switch The Mode switch setting determines both the process and output On Off control see Sec tion 5 3 Source of control panel or remote for the amount of output is selected on the Voltage Amperage Control switch For Air Carbon Arc CAC A cutting and gouging place switch in Stick position For a BO ND best results place Inductance Dig control in the maximum position 6 Control Switch For front panel control place switch in Panel position For remote control make connections to Re mote 14 receptacle and place switch in Remote position In most modes remote control is a percent of the Voltage Amperage Adjustment control setting the value se lected on Voltage Amperage Adjustment control is maximum available on remote In the MIG mode remote control provides full range of unit output regardless of V A Adjust control setting 7 Inductance Dig Control Control adjusts Dig
46. icates a shorted thermistor RT2 on the left side of the unit If this display is shown con tact a Factory Authorized Service Agent 2 Help 1 Display Indicates a malfunction in the primary power circuit If this display is shown contact a Fac tory Authorized Service Agent 3 Help 2 Display Indicates a malfunction in the thermal protection circuitry located on the left side of the unit If this display is shown contact a Factory Authorized Service Agent 4 Help 3 Display Indicates the left side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 4 2 Operation will continue when the unit has cooled 5 Help 4 Display Indicates a malfunction in the thermal protection circuitry located on the right side ofthe unit If this display is shown contact a Factory Authorized Service Agent 6 Help 5 Display Indicates the right side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 4 2 Operation will continue when the unit has cooled 7 Help 6 Display Indicates that the input voltage is too low and the unit has automatically shut down Opera tion will continue when the voltage is within the acceptable lower range limit 1596 below the applicable input voltage If this display is HE L HE L HE L HE L HE L P 5 IH NI Hi Hi shown have an electrician check the input voltage 8 Help7 Display Indica
47. in 1in 18 mm 7087 in 27 mm 27 mm 3 4 in 750 in 1 1 8 in 1 1 8 in 22mm 8661 in 32 mm 32 mm 7 8 in 875 in 1 5 16 in 1 5 16 in 24 mm 9449 in 36 mm 36 mm 1in 1 000 in 1 1 2 in 1 1 2 in Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or
48. ional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble 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 recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles
49. irator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes 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 Use protective screens or barriers to protect others from flash glare and sparks warn others n
50. lso 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 output in damp areas if movement is confined or if there is a danger of falling 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 follow ing 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 unavoid able 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 volt age 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 ins
51. ments phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to b
52. nce Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux e
53. ot to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding 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 e 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 weld 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 may 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
54. re welding E 150 NOTICE Exceeding duty cycle can damage unit and void warranty 10 15 20 25 30 40 50 60 70 80 90 100 ADUTY CYCLE 60 Duty Cycle d did 6 Minutes Welding 4 Minutes Resting Overheating 0 A oo Minutes Reduce Duty Cycle Ref SA 178 651 OM 233 045 Page 15 4 3 Volt Ampere Curves A CC Mode 100 80 SMAW MAX yy 60 GTAW MAX 7 40 GTAW MN SMAW MN 20 H 25 ARC CONTROL 50 i 10 100 200 300 400 AMPERAGE 500 Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown CV Mode 100 80 o 60 o e gt 40 MAX E 20 MIN 0 1 1 1 1 100 200 300 400 500 AMPERAGE va_curve1 4 95 SA 178 652 SA 178 653 OM 233 045 Page 16 4 4 Selecting A Location gt EN Dimensions Weight 87 Ib 39 5 kg 17 in 432 mm 12 1 2 in 318 mm Ne Movement 1 Lifting Handles Do not move or operate Use handles to lift unit unit where it could tip 2 Hand Cart Use cart or similar device to move unit 3 Plate Label Use label to determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are
55. setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e 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 elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 233 045 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Docu
56. ssurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SA o LETES peuvent provoquer des bles sures dans les yeux Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester dista
57. t raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Lecouvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables Ne pas installer l appareil proximit de pro duits inflammables Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser Vanneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des
58. t rated frequency 10 and voltage 10 Phase to ground voltage shall not exceed 10 of rated input voltage Do not use genera tor with automatic idle device that idles engine when no load is sensed to supply input power to this welding power source NOTICE Actual input voltage should not be 1096 less than minimum and or 1096 more than maximum input voltages listed in table If actual input voltage is outside this range output may not be be available A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 50 Hz Three Phase Input Voltage 400 Input Amperes At Rated Output 18 Max Recommended Standard Fuse Rating In Amperes Time Delay 20 Normal Operating 25 Min Input Conductor Size In AWG 14 Max Recommended Input Conductor Length In Feet Meters 133 41 Min Grounding Conductor Size In AWG 14 Reference 2005 National Electrical Code NEC includes article 630 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable betwe
59. talling or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions PK This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards 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 conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced 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 Do not touch electrode holders connected to two welding ma chines at the same time since doubl
60. tes that the input voltage is too high and the unit has automatically shut down Operation will continue when the voltage is within the acceptable upper range limit 1596 above the applicable input voltage If this display is shown have an electrician check the input voltage Help 7 can also indicate a bus voltage imbalance 9 Help 8 Display Indicates a malfunction in the secondary power circuit of the unit If this display is shown contact a Factory Authorized Ser vice Agent 10 Help 9 Display Indicates a shorted thermistor RT1 on the right side of the unit If this display is shown contact a Factory Authorized Service Agent OM 233 045 Page 27 6 4 Troubleshooting 3 NN gt Trouble Remedy No weld output unit completely inop erative Place line disconnect switch in On position see Section 4 9 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 9 Check for proper input power connections see Section 4 9 No weld output meter display On If using remote control be sure Mode Selector switch is in a position that provides output control at Remote 14 receptacle Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 4 2 Erratic or improper weld output Use proper size and type of weld cable see Section 4 5 Clean and tighten all
61. torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de Vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 233 045 Page 9 OM 233 045 Page 10 3 1 SECTION 3 DEFINITIONS Manufacturer s Warning Label Definitions Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes
62. traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 233 045 Page 2 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 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding 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 by pass them Follow requirements in 1910 252 2 and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shutoff shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going n
63. uca Les Mas na 2 ECT ER 179 309 Label Caution Falling Equipment 2 E HD1 182918 Transducer Current 400A Module Supply V 15V 1 Lo 203342 Bus Bar Current Sensor 1 RERO ES 203341 Bus Bar Output Rectifier 1 vel Le anda AE 181853 Insulator Screw 4 AB ex D1 2 201 531 Kit Diode Power Module 2 cies Des iia 6 229 967 Circuit Card Assy Input 1 EE 187 219 Spacer Nylon 208 Od 375 Id X 750 Lg 1 ER 187 146 Bracket Mtg Filter Board 1 EE IE 179 276 Bushing Snap In Nyl 1 000 Id X 1 375Mtg Hole 2 12 C5 6 R1 232296 Resistor Capacitor Assy 1 13 RT1 2 173 632 Thermistor NTC 30K Ohm 2 TE 185 836 Label Warning Exploding Parts 2 udo itor ip 183 551 Windtunnel LH 1 1 1 ES bs 604 176 Receptacle Str Dx Grd 2p3W 15 125V 1 Sb vd 234 126
64. urces de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent dangereux I Le soudage des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form
65. weld connections No 110 volts ac output at duplex recep tacle Remote 14 receptacle Reset circuit breaker CB1 see Section 4 7 No 24 volts ac output at Remote 14 re ceptacle Reset circuit breaker CB2 see Section 4 7 OM 233 045 Page 28 197 552 OM 233 045 Page 29 SECTION 7 ELECTRICAL DIAGRAM eA WHT e Y Bi Les a Elsie sale oi 1 e e GENDE 15 1 TO 5 Um 1 I lo I 3 I n S 8 PEL 9 FN PC6 lr N 52 000 2 2 53 mn Tr oge RC3 PLG21 n 1 ES EK EO 2 o z lt lt RES 35 2 lt lt RC3 3 ci gt RC10 N ot 1 3 2 4 ni i aa aa PERIOD aur 2 999 x 2 2 N 8 O 0 Q Q 9 o vv x m Y Y Y rF ZzF VV I 1655550 Www Iz T2 5 P quy ge a 118V ETE EE EL ES d I I yyy 29 I v v I 10 7 9 Y Y Y DUTY por Pos 9 5 D D RCI PLG15 2055 RC1 PLG16 dc c dc
66. when a Stick SMAW welding position is selected on mode switch 214 740 A When set lower short circuit amperage at low arc voltage is the same as normal welding amperage When set higher short circuit amperage is in creased at low arc voltage to assist with arc starts as well as reduce sticking while weld ing see volt ampere curves in Section 4 3 Select setting best suited for application Control adjusts inductance when a MIG GMAW position is selected on the mode Switch Inductance determines the wetness of the weld puddle When set higher wet ness puddle fluidity increases When pulsed MIG or one of the TIG GTAW processes is selected this control is not func tional OM 233 045 Page 22 5 2 Meter Functions gt The meters display the actual weld output values for approximately three seconds after the arc is broken Mode Meter Reading At Idle V A EF Scratch Start TIG GTAW 80 0 85 Actual Volts OCV Preset Amps V A r La wrt Lift Arc Trigger Hold TIG GTAW 85 Blank Preset Amps V A IF sg TIG GTAW 85 Blank Preset Amps V A G MIG GMAW 24 5 Preset Volts Blank V A Pulsed MIG GMAW P PPP PPP Pulse Display Pulse Display V A c Remote 7

Miller Electric XMT 304 CC/CV User's Manual

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