Miller Electric DS-2 User's Manual
Contents
1. Arc Welding Hazards Additional Symbols For Installation Operation And Maintenance Principal Safety Standards EMF Information SECTION 2 DEFINITIONS 2 1 Warning Label Definitions SECTION 3 INSTALLATION 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 Specifications Site Selection Equipment Connection Diagrams ci Installing Wire Guides And Drive ROIS ces eras ei beta ewe ere Aer Etre 10 Pin Plug PLG8 Information ooooocococococc III TPN Plug PLGA MO Mal caia nao VE ni Mines Die Net Ses 10 Pin Plug And Shielding Gas Connections Connecting Weld Cable Connecting Welding Gun 3 10 Changing Nameplates 3 11 Installing Wire Spool And Adjusting Hub Tension 3 12 Threading Welding Wire SECTION 4 OPERATION 4 1 Pendant Controls SECTION 5 MAINTENANCE amp TROUBLESHOOTING 4 4 5 1 Routine Maintenance 5 2 Troubleshooting SECTION 6 ELECTRICAL DIAGRAM 50063006353 33 pit DIR A A SECTION 7 PARTSLIST SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ds AM Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Means Note2. 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 standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsi
3. not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit AM 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 e 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 t
4. Customer Sup plied Select weld cable according to welding power source Owner s manual Install female weld cable connec tor as shown 3 Male Weld Cable Connector Connect male and female weld cable connectors Ref ST 802 483 A OM 197 509 Page 9 3 9 Connecting Welding Gun Tools Needed C XHA 5 16 in OM 197 509 Page 10 1 Gun Securing Knob Loosen knob 2 Gun Block 3 Gun End Slide gun end as far as possible into gun block and tighten gun se curing knob 4 Gun Trigger Plug Connect gun trigger plug to match ing receptacle on wire feeder Ref ST 802 483 A 1 Pendant 2 Nameplates Pendant has three nameplates stacked one on top of the other Each nameplate contains the volt age and amperage ranges for a dif ferent size flux cored welding wire for reference only Unit is shipped with 1 2 mm wire nameplate on top To change to 1 4 mm or 1 6 mm wire nameplate re move the four screws and bring the desired nameplate to the front Install the four 4 screws back in place to hold the nameplates Ref ST 802 483 A 3 11 Installing Wire Spool And Adjusting Hub Tension 1 Hub Support Arm 2 Spool Hub 3 Retaining Ring 4 Hub Pin Remove retaining ring Slide wire spool onto spool hub so wire feeds off bottom of spool Install spool so hub pin fits spool hole Reinstall re taining ring 5 Tension Nut Adjust tension nut so a slight force is needed to turn spool When a
5. Head Feed OO 2 snos id ain d 194 799 Kit Drive Roll Vk 1 2 1 4 Uat 9194 797 Kit Drive Roll Vk 1 6 1 7 OT end tae 197 309 Inlet Guide 1 2 1 6 2x TOT 197 311 Inlet Guide 1 6 1 7 DP NEM 196 945 Motor Drive Assy Wire o RNC PRENNE 196 956 Label Warning Electric Shock And Pinch Wordless QA A TE 197975 s PUJ CAD iss AER ILE RES doses Dudum iod 199 927 Cable Weld ia suoni bra decide kc tegi PO saat autem ot 042 534 Connector Kit Dinse 1 Plug 1 Rept 70mm CN nce se eek 203 363 Cord Power OO icant age 010916 Conn Clamp Cable 750 A EEA 127 854 Clamp Stl Cush 1 312 Dia X 343 Mtg Hole OPTIONAL Quantity When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 197 509 Page 19 L 3ardware is common and not available unless listed Ref 802 586 Figure 7 2 Pendant Assembly Item Dia Par NO Mkgs NO Description Quantity Figure 7 2 Pendant Assembly Figure 7 1 Item 5 le 196949 Box Pendant ee at eich a aaa io d 1 P PNE 035897 Pot Cp Std Slot 1
6. Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 197 509 Page 3 1 5 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 committee s 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 be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 197 509 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from
7. slight force is needed to turn spool tension is set Tools Needed YT 15 16 in Ref ST 802 483 A Ref ST 072 573 B OM 197 509 Page 11 3 12 Threading Welding Wire 1 Pressure Assembly 2 Pressure Assembly Adjustment Knob Lay gun cable out straight A Open pressure assembly hold wire tightly and cut off end Push wire through guides into gun B Close and tighten pressure assembly and let go of wire C To adjust drive roll pressure press gun trigger to feed wire against wood surface Tighten knob so wire does not slip Cut off wire Z q Tighten Tools Needed EF Ref ST 802 483 A OM 197 509 Page 12 SECTION 4 OPERATION 4 1 Pendant Controls DS 2 WIRE FEEDER 27 29 1 I 31 DS 2 WIRE FEEDER 2 25 27 2 y 4 Controls are pendant mounted An optional remote pendant extension cord is available 1 Nameplate Pendant has three nameplates stacked one on top of the other Each nameplate contains the voltage and amperage range for a differ ent size flux cored welding wire for reference only Unit is shipped with 1 2 mm wire nameplate 25 V E o A olo mpm on top See Section 3 10 to change to 1 4 mm or 1 6 mm flux cored welding wire nameplate 2 Voltage Control Use control to set welding power source volt age at the wire feeder Numbers are for refer ence only 3 Wire Speed Control Use control to adjust wire feed speed from 0 to 20
8. OM 197 509B July 2002 Processes MIG GMAW Welding fe Flux Cored FCAW Welding FC Description 2i ES Wire Feeder y ZA b SA LD Ro C Visit our website a OWNER S MANUAL 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 Ir RU E Bl U El ISR 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 i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick A warranty in the and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair th
9. alified 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 e f notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual 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 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA
10. ations 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 6 02 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA 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 File a claim for loss or damage during shipment 2002 Miller Electric Mfg Co 5 02 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 Uni
11. ays 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 197 316 OM 197 509 Page 5 SECTION 3 INSTALLATION 3 1 Specifications Wire Diameter Range Welding Power Type of Input Wire Feed Source Type Power Speed Range Welding Circuit Overall Rating Dimensions Solid Wire 045 To 1 16 in 24 Volts DC 5 1 2 To 1 6 mm 38 Volts Length 20 7 8 in Deltaship Amp For Wire 350 Amperes 530 mm Constant Voltage Feed Motor 0 to 780 ipm Flux Cored Wire 100 Duty Cycle Width 9 in 229 CV DC With 24 Volts AC 0 5 0 To 20 mpm 045 To 068 in mm 10 Pin Receptacle Amp For Gas 1 2 To 1 7 mm Height 13 3 4 in Valve Max Spool 286 mm Weight 44 lb 20 kg 17 5 Ib 8 kg 3 2 Site Selection 1 Wire Feeder 2 Gas Cylinder Customer Supplied Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip Ref ST 802 483 A OM 197 509 Page 6 3 3 Equipment Connection Diagrams Deltaship 502 Welding Power Source With 24 VAC Power 10 Pin Control Cord Positive Weld Cable Customer Supplied Work Cable Customer Supplied Work Wire Feeder Welding Gun Gas H
12. ce feeder see welding power source owner s manual light on Unit overheated Allow unit to cool with fan On see welding power source owner s manual Have Factory Authorized Service Agent check control board PC1 and or motor drive board PC2 Unit provides only maximum or Have Factory Authorized Service Agent check control board PC1 motor drive board PC2 and Hall minimum weld output Device HD1 Erratic or improper weld output Use proper size and type of weld cable see welding power source owner s manual Clean and tighten all weld connections Check wire feeder installation see Section 3 3 Use proper tap on stabilizer see welding power source owner s manual Have Factory Authorized Service Agent check control board PC1 motor drive board PC2 and or SCR in main rectifier No 115 volts ac output at duplex re Reset circuit breaker CB1 See welding power source owner s manual ceptacle OM 197 509 Page 14 Fan in welding power source not oper Check for and remove anything blocking fan movement ating Note fan runs only when cool Have Factory Authorized Service Agent check fan motor ing is necessary Wire does not feed unit completely Check 10 pin plug PLG8 connections see Section 3 7 inoperative Check input power Wire does not feed Check circuit breaker CB2 on welding power source and reset if necessary see welding power source owner s manual Check gun trigger connection at wire feed
13. er see Section 3 9 Check gun trigger leads and trigger switch Have Factory Authorized Service Agent check drive motor control board PC1 and motor board PC2 Wire feeds erratically Readjust hub tension and drive roll pressure see Section 3 11 and 3 12 Use correct size drive roll see Parts List Wire feeds when Jog switch is pressed Check gun trigger connection at wire feeder see Section 3 9 Check gun trigger leads and trigger but not when gun trigger is pressed switch Wire feeds as soon as power is applied Check gun trigger Wire does not feed until trigger is Check position of Mode switch on welding power source This is normal operation when switch is in pressed but continues to feed after Crater Fill On or Trigger Hold On positions see welding power source owner s manual trigger is released Check for short between gun trigger leads and weld cable Repair or replace gun trigger leads Gas valve rattles loudly and wire feeds Check for short between gun trigger leads and weld cable Repair or replace gun trigger leads slowly or erratically Gas does not flow wire feeds Check gas valve and flowmeter OM 197 509 Page 15 SECTION 6 ELECTRICAL DIAGRAM WARNING Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install TRIGGER GAS VALVE 203 365 Figure 6 1 Circuit Dia
14. ere s a Troubleshooting section that will REGISTERED QUALITY SYSTEM 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 ee exact part you may need to fix the problem the ISO 9001 Quality System Warranty and service information for your Standard particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P 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 orindividual catalog 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 ur Miller WARNING This product when used for welding or cutting 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 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 2 1 3 1 4 1 5 Symbol Usage
15. gram For Wire Feeder OM 197 509 Page 16 Notes OM 197 509 Page 17 SECTION 7 PARTS LIST E Hardware is common and not available unless listed 5 Fig 7 2 6 JE 25 de Ref 802 586 Figure 7 1 Main Assembly OM 197 509 Page 18 Item Par No No Description Figure 7 1 Main Assembly de hand EEE 072094 Hub Spindle Assy 196 937 Assembly Frame SR UR 196 954 Grip Handle ME 196951 Knob Pendant STERNEN 196 948 Pendant Feeder Figure 7 2 SER RER ENG 197 316 Label Warning General Precautionary Wordless Wf Has is ne in 125 785 Valve 24vac 2way Custom Port 1 8 Orf W Frict Ourada neers ds 112863 Ftg Hose Brs Barbed M 1 4 Tbg X 5 8 18 Sae Flare AA Me Re 149 332 Clamp Hose 405 485 Clp Dia Slfttng Olive Dra Tc scorre 095 637 Hose Sae 187 Id X 410 Od X 13 000 Dicis 199 846 Conn Circ Cpc 7skt Size 13 Recpt Panel Pushin qc EOS 048 282 Conn Circ Cpc 4skt Size 11 Rcpt Panel Pushin jo P 193 707 Guide Wire Adapter 1 2 1 6 Sasse 197 175 Guide Wire Adapter 1 6 1 7 RA 196 946 Insulator Gun Block jEc TE 079 633 Ftg Hose Brs Barbed Nipple 3 16 Tbg Or o 193 681 Block Connector Gun Miller PAR et batts 196 947 Knob Gun Block TO supe Sp E 196 944 Drive Assy wire consisting of cia 197305
16. he welding process e f AC output is required use remote output control if present on unit 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 and ground 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 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 som nd 4 98 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards f 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 Repa
17. ir 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 e 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 after removal of input power on inverters Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts 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 f inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases f ventilation is poor use an approved air supplied respirator Read 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
18. l 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 Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 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 weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards 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 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 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 FLYING METAL can injure eyes pe Welding chipping
19. meters per minute v N 21 u o O o 5 45 1 L I 4 12 Ref ST 802 483 A ST 199 348 ST 199 350 199 343 Use Nameplates As A Voltage And Amperage Reference Only DS 2 WIRE FEEDER 25 oa 33 Ld 35 _ 37 39 4 O 1 6 mm 15 CORED WIRE Ld E C Miller bj 20 Match colored bands on voltage and wire speed controls to get an acceptable welding condition 4 Jog Switch Use Jog switch to momentarily feed welding wire at speed set on Wire Speed control with out energizing welding circuit or shielding gas valve OM 197 509 Page 13 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance 4 Disconnect power before maintaining Te f Repair Or AR Clean And K Replace Replace N Tighten Unreadable Labels Cracked Weld Weld Cable Terminals Replace Cracked Parts 10 Pin Cord Blow Out Or Vacuum Inside During Heavy Service Clean Monthly Trouble Remedy No weld output unit completely Place line disconnect switch in On position see welding power source owner s manual inoperative Check and replace line fuse s if necessary or reset circuit breaker see welding power source owner s manual Check for proper input power connections see welding power source owner s manual Check for proper jumper link position see welding power source owner s manual No weld output Power switch pilot Check repair or repla
20. n or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limit
21. n a pressurized cylinder explosion will result Use only correct shielding 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 Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols 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 UNIT can cause injury 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 f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING 23 iie e Ne 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 STATIC ESD can damage PC boards J Put on grounded wri
22. nal distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Grids Maxstar 85 140 Spot Welders Load Banks 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 6 Months Batteries 4 5 90 Days Parts Miiller MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT 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
23. ose Customer Supplied Sy 1 Pressure Assembly Knob M 2 Pressure Assembly Arm Move Knob to the right and pres sure arm pops up 3 Inlet Wire Guide 4 Inlet Wire Guide Securing Screw Tools Needed EE B To change inlet wire guide loosen screw and remove guide 5 Outlet Wire Guide 6 Outlet Wire Guide Securing Screw To change outlet wire guide loos en screw and remove guide out front of gun block 7 Lower Drive Roll 8 Coned Spacer Washer 9 Thumb Screw To change drive roll remove thumb screw and coned spacer washer and slide drive roll off shaft Be sure holes in drive roll line up with pins on gear 10 Retaining Clip 11 Upper Drive Roll 12 Gear 13 Pin To change upper drive roll remove retaining clip from pin Slide pin out and lift drive roll and gear out of pressure arm When installing upper drive roll be sure holes in drive roll line up with pins on gear 14 Drive Roll Size When installing a drive roll either into the pressure arm or onto the lower gear adapter install drive roll with the wire size stamp of the wire being used i e 1 2 mm facing the operator even though the corre sponding wire groove is on the op posite side of the drive roll Corresponding 1 2 mm Wire Groove 1 2 mm Wire Size Stamp Ref ST 802 483 A ST 802 481 OM 197 509 Page 7 3 5 10 Pin Plug PLG8 Information AP to mat n Lr lic cia I se 10 vol
24. r is there to help you every step of the way Effective January 1 2002 Equipment with a serial number preface of LC 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 IS 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 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an Internatio
25. st strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards Uy SS MOVING PARTS can cause injury Keep away from moving parts e 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 Do not point gun toward any part of the body other people or any metal when threading welding wire 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qu
26. t 2 W 1k Linear 1 dui 073562 zus Pot Cp Std Slot 1t 2 W 10k Linear 1 4 021467 Switch Tgl Spst 3a 250v Off none On Spd Term 1 es 189404 Space INVIO Rs en ne end era eco be 1 Dat 196950 x sachs haere Cover Pendant serien ee A CAM e He aca dde ME 1 ran 196943 Nameplate Pendant 1 2 mm eens 1 PIN 199348 Nameplate Pendant 1 4 mm 1 Dee 199350 Nameplate Pendant 1 6 mm 1 lors 097922 ne Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 2 1h 232 196955 ans Gora Pendant 2 55 o acus naeh voltajes 1 OUO 070584 Tubing Gl Acryl 129 141 ld 9xspool Yel Fat 0 5 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 197 509 Page 20 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 Mille
27. ted Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Jn Miller
28. the breathing air is safe 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 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 if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 197 509 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays De ee burn eyes and skin Sparks fly off from the weld Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 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 and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather and wool and foot protection FRA 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 Accidenta
29. 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 possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 DEFINITIONS 2 1 Warning Label Definitions A Warning Watch Out There are possible hazards as shown by the symbols A B Drive rolls can injure fingers C Welding wire and drive parts are at welding voltage during operation keep hands and metal objects clear 1 Electric shock can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 196 956 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc r
30. ts de input 0 to 10 volts dc output from min to max of Wire Speed control R2 15 volts dc with Jog switch S3 open 0 volts dc with switch closed Motor positive 0 to 24 volts dc input to wire drive motor M1 with respect to pin I AN Motor negative 3 6 7 Pin Plug PLG1 Information 197 504 3 7 10 Pin Plug And Shielding Gas Connections Tools Needed IO 11 16 in OM 197 509 Page 8 m man L 5 0 to 10 volts dc output from min to max of Output Command control R1 a 0 to 10 volts dc output from min to max of Wire Speed control R2 15 volts de with Jog switch S3 open 0 volts dc with switch closed 1 Gas Hose Customer Supplied Connect to gas supply 2 10 Pin Plug PLG8 Use plug to make connection to welding power source 3 Weld Cable w Quick Connect Ref St 802 483 A 3 8 Connecting Weld Cable Connector Body Male Or Female om m Sleeve Weld Cable 7 Insulator Push weld cable through insulator as shown Remove 1 in 25 mm of insulation from end of cable Install supplied sleeve on stripped end of cable Insert cable with sleeve into connector body so that cable is snug and against bottom of connector body Install and tighten setscrew with supplied hex wrench to se cure connector body onto cable Push insulator onto connector body to cover setscrew 1 Female Weld Cable Connec tor Supplied 2 Weld Cable
31. 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 OM 197 509 Page 2 Shut off shielding gas supply when not in use Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding 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 mechanical shocks 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 o
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