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Miller Electric Axcess 300 User's Manual

1. to filter board ground terminal CE 5 16 in applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief and tighten screws Use large strain relief for input conductor size 8 and larger Use small strain relief with reducing washers for input conductor size 10 Connect input conductors as shown in illustration Route green or green yellow grounding conductor through current transducer and connect to welding power source grounding terminal first Then connect input conductors L1 L2 and L3 to welding power source line terminals Reinstall side panel onto welding power source Route input conductors Route ground conductor through tubing and cur rent transducer to 804 650 A Ref 803 855 A Ref 803 766 A 219 842 A Disconnect Device Power Connections Input 3 Disconnect Device switch shown in the OFF position 4 Green Or Green Yellow Grounding Conductor 5 Disconnect Device Grounding Terminal 6 Input Conductors L1 L2 And L3 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect
2. 1 saan NP eee ee eae Fig 11 5 Front Panel Assembly 1 DEDERE T 227855 Kit Connectors W Washer For Power Cables Includes 1 MERI CIPUE 010467 Connector Clamp Cable 1 250 1 sears LS tee artes am sessi eet 225840 Washer Reducer 1 25 in 0 75 in 2 ce PAH 010916 Connector Clamp Cable 0 750 1 Recommended Spare Parts 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 230 032 Page 41 F Hardware is common and not available unless listed ES 802 955 A Figure 11 2 Windtunnel Assembly LH And RH Item Dia Par No Mkgs No Description Quantity Figure 11 2 Windtunnel Assembly LH And RH Fig 11 1 Item 6 oes TAY tse uem 214597 Windtunnel LH w Components including 1 de 196351 Windtunnel LH 2222 1 TAE DET L1 S 213940 Inductor Input 1 skr PENA as 214519 Insulator Heat Sink Rectifier
3. 1 Recommended Spare Parts 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 230 032 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 11 2 Windtunnel Assembly LH And RH Continued Fig 11 1 Item 6 SAF 20G NA ES 201695 Clamp Capacitor Bottom 2 21 01 02 226081 Capacitor Elctlt 2400 Uf 500 Vdc Can 2 50 Dia 2 BD of ac ceeds Ure eh 210507 Clamp Capacitor Top Machined 2 Usi AA 217625 Kit Input Pre regulator And Inverter Module 2 24 RT1 RT2 214015 Thermistor NTC 30K Ohm 25 Deg C 7 amp 18in Lead 1 a BB aan POZ scs 222661 Circuit Card Assy Power Interconnect 1 26 C3 196143 Capacitor Polyp Met Film 16 Uf 400 VAC 10 1 man PA Paanan aa ae 196378 Bracket Mtg Current Xfmr 1 28 HD1 182918 Transducer Current 400A Module Supply V 15v 1 MA AA deer dean ee 196384 Cable Transducer 20in 1 ic
4. 1 ii Dp ae RC 233052 Resistor Capacitor 1 IE KC PME 199840 Bus Bar Diode 00000 a eee tenet nner hm nn 2 7 Di D2 201531 Kit Diode Power Module 2 ae LONDON NON 196347 Heat Sink Rectifier 0 II 1 E een Eat atts 196349 Spacer Windtunnel 3 10Q T palag 203408 Xfmr HF Litz Litz rm na III 1 xs in Ll 220496 Output Inductor Assy 1 ERU CUTE 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 2 A V pur 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole Cent 4 mur 1963552 INSULTO SC Wa uae Da aa tore Ele co ln de d th a 6 RN I P NEN EUM 010546 Bushing Snap in Nyl 375 Id X 500 Mtg Hole 1 A WO Sut kapa 222958 Windtunnel RH w Components including 1 rc 196332 Windtunnel RH 2 00 cece eens 1 AB i tei Cos bcn 030170 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole Cent 2 is 196259 Plugs w Leads 8 Current Xfmr including 1 TI 115092 Housing Plug amp Skts PLI 115091 Housing Plug amp Skts 1 ET CT4 196231 Xfmr Current Sensing 200 1
5. FE Weld Process Board PC4 Diagnostic LED s 1 Weld Process Board PC4 Diagnostic LED s are visible inside unit located on PC4 mounted on the top tray Refer to Section 9 3 for information on diagnostic LED s Reinstall cover after checking diagnostic LED s 214763B 1 321 DELL me ua niii us CONTRE ne Tun si nim o E minim Er rear OR ES 5 110909 RE 15 m 1 LED1 LED2 LED3 LED4 216 956 A Ref 803 670 A 9 3 Diagnostic LED s On Process Board PC4 LED Status Diagnosis 1 On Indicates 25 volts dc is present on process board PC4 Off Indicates 25 volts dc is not present on process board PC4 2 On Indicates 25 volts dc is present on process board P
6. OM 230 032C 2007 10 m Processes Miller ne ouam year e Pulsed MIG GMAW P Flux Cored FCAW Welding 4 Automatic Welding Description AZE Automatic Welding Interface And Arc Welding Power Source C Axcess 300 OWNER S MANUAL File Advanced Manufacturing Systems NY ES Visit our website at www MillerWelds com ams 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 3 Bl E Kisa 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 2 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
7. SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power e 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 pasa OM 230 032 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 respirator 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 re
8. Figure 11 4 Rear Panel Assembly Fig 11 1 Item 8 A a 210478 Panel Rear 1 DR nae a 2103582 Eye Bolte sin r R A A CIA Ae SRM 1 QE m co dire 219929 Nameplate Rear 1 a qo ar 217297 Cover Receptacle Weatherproof Duplex Rept 1 MX RN A 210483 Bracket lift eye 1 6 CB1 083432 Supplementary Protector Man Reset 1P 10A 250VAC Frict 1 Paa B2 5 093995 Supplementary Protector Man Reset 1P 15A 250VAC Frict 1 8 RC2 196814 Receptacle w Leads 115V Duplex 1 us Oi sss POT2S Ls 209676 Circuit Card Assy E Stop 1 AMO A 115440 Stand off no 6 32 x 687 lg 250 hex alfem 4 CA a 212764 Plug Assy Rear 1 Recommended Spare Parts 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 230 032 Page 45 F Hardware is common and not available unless listed 15 Ref 804 676 A Figure 11 5 Front Panel A
9. H l 70 1 E I l 68 iT z 228 PACA ITR ml VA Q 11 FS A 19 704 REMOVE FOR El i RO4 125 stor COMBO RG4 2 gt gt ADD FOR ESTOP PCI2 pas COMBO E STOP Dr Ree 728 Aa m icy BOARD RCD D gt OF ro1 ru673 RC2 6 gt RC2 PLG76 RO2 4 gt gt gt 3 RC3 PLG9D 65 Raza 3 RC4 PLG4G ya Res gt HE Ros 2 gt gt O RCS 3 gt gt 2 __ A Ht RG3 1 gt gt RG7 1 Lecce ADD FOR sago MOVE 101 FROM RC7 1 TO RC3 4 FOR ESTOP COMBO RCA 115V REPT RD PLO7O Y pong 2N WAET R 21 PLC2I 12 1N HAT A DANG 3 15 8 Figure 10 1 Circuit Diagram For Welding Power Source OM 230 032 Page 38 amp WARNING e Do not touch live electrical parts _Y e Disconnect input power or stop engine before servicing J Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit Ka 3 i Ed 10 3 3 TERRIER TYP 3 ONG y NVERTER NODULE 1 z1 x R
10. 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 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 delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Yea
11. 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 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 assurez 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 NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES e SALETES peuvent provoque
12. i R HEN K Ea 2 2 St NS az X NANNANAT TI AFd 32222 BEBE rus gt gt ARS mar RE4 7 gt gt v INDUCTOR Pat CONTROL BOARD RCZ PLCZ RCXY PLO3 INTEROONNECT 12 BOARD RE4 PLEA RGO PLGO T yagi p ngayo R973 vli ROB PLE14 Nube ey lt REI 3 Lil RO9 1 gt n BUS SENSE 8S7 RE RC10 P G10 RC9 8 gt Te reo ros ROS gt ag rei Fc res ROB 5 gt u RCI 5 TT ut RCg 4 gt w RE1 4D t Kes ROO_5 gt gt u reis Z Kers ROS 1 0 gt id cHasas re1 7 KG lt ROE T RESI 1 gt gg m AG AGZ AGS Re1 2 gt gt _ _ crea RC 1 227 o ro hors RO9 2 gt RC 5 gt Rei 1 gt A ROB 3 PC3 N ro ton SauacT Tart nD KULAY 85888838 3888 3 ES OEC EX EXE 4 RC1 FLCIE Ly Y Y v X Y Y Y Y XY Y Y RC2 PLG19 3 aag RI R RI RI Sas Isa e lt RC2 3 L J NOTE POWER CABLE TO BE NEON O5 SUPPLIED de INSTALLED 9 E db BY CUSTOMER UNG PLGBU HD2 I P374 PM R PC14 ar Ka NG Sta AC L2 fle el 3 FERRITE NOT READY 4B SUMMED HB SIMMED COR OC LATCH COMMAND COMMAND COM VER THER COW ACTOR 175 VAL 14 LAC 18 VAC 229 810 A OM 230 032 Page 39 SECTION 11 PARTS LIST F Hardware is common and not available unless listed 4 Fig 11 3 6 Fig 11 4 18 20 17 Fig 11 5 Ref 804 651 A Figure 11 1 Main Assembly OM 230 032 Page 40 Item Dia Part No Mkgs No Descriptio
13. 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 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 Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool W
14. t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 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 Q 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 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 230
15. 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 95 420 dom 4 2ea 2 0 2ea 2 250 2 35 1 50 1 0 60 2 0 70 3 0 95 020 Do rn 4 0 2 ea 2 0 2 ea 3 0 2 ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2x95 4 0 2 ea 2 0 2 ea 3 0 2ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2x95 2x120 4 0 2 ea 2 0 2 ea 3 0 2 ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2x120 2x120 2 ea 2 0 2 ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 soo 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 Positive Negative 2 ea 2 0 2ea 3 0 2 ea 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 Ref 803 669 A 700 4 0 120 2 ea 2 0 2 ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 4 0 3 ea 4 0 4 ea 4 O 120 2x70 2x95 2x120 3x95 3x120 3x120 4x120 800 4 0 120 2 ea 2 0 2 ea 3 0 2 ea 4 0 3 ea 4 0 3 ea 4 0 4 ea 4 0 4 ea 4 0 2x70 2x95 2x120 3x120 3x120 4x120 4x120 This chart is a general guideline and may not suit all applications If cable overheating occurs use next size larger cable Cable should be
16. A 1 Power Switch 2 Pilot Light 3 PDA Port Turns unit On or Off Light indicates status of welding power 4 PC Port Source on when unit is on and off when unit is off 6 2 Options A E Stop Option The E Stop option comes with a 2 pin amphenol receptacle matching plug and 30 ft 9 m of high density molded cord to allow connecting the welding power source into an E Stop circuit An integrator will need to supply a closure for the non E Stop condition When the E Stop input connection changes it state from closed to open the welding power source goes into an E Stop mode where all welding outputs shutdown immediately Once the input connection returns to a closed state the unit will start a reset routine and be ready for opeation when it completes the reset operation B DeviceNet Option The DeviceNet option provides hardware and software that allows the welding power source to be connected into a DeviceNet network Contact factory for option details C RMD Option RMD Regulated Metal Deposition is a precisely controlled short circuit transfer welding process Some of the bene fits provided by the RMD process are the ability to weld thin gauge material and use larger diameter welding wire on thin gauge material improved gap filling reduction of spatter less heat input into the workpiece and less distortion The RMD process is a software option that is loaded into the welding power source Contact factory for option detail
17. Do not place anything between weld cable terminal and copper bar Tools Needed TI 3 4 in 19 mm Correct Installation A Turn off power before connecting to weld output terminals A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine Determine total cable length in weld circuit both positive and negative cables com bined and maximum welding amperes See Section 5 1 to select proper cable size 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal Connect positive weld cable to Positive weld terminal and negative cable to Negative weld terminal 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal Incorrect Installation Ref 803 667 A 803 778 A 6 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean OM 230 032 Page 18 4 9 Network Wire Feeder Receptacle Functions A remote Pin Pin Information A Not used B Shield C Volt sense D Can low
18. NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 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 between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 230 032 Page 20 4 11 Connecting Input Power Tools Needed SS A Turn Off welding power source and check voltage on input capacitors according to Section 9 1 before proceeding Installation must meet all National and Local Codes have only qualified persons make this installation Disconnect and lockout tagout input power before connecting input conductors from unit Make input power connections to the welding power source first gt gt P P Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 10 Conductors must comply with national state and local electrical codes If
19. TEN boards or parts Veo e Use proper static proof bags and boxes to store move or ship PC boards OM 230 032C 2007 10 safety stm 2007 04 F Indicates special instructions n 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 FIRE OR EXPLOSION hazard e Do not place unit on over or near combustible surfaces e Do not service unit near flammables FLYING METAL or DIRT can injure eyes e Wear safety glasses with side shields or face shield during servicing e Be careful not to short metal tools parts or wires together during testing and servicing EIC HOT PARTS can cause severe burns Do not touch hot parts bare handed e e Allow cooling period before working on equipment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns EXPLODING PARTS can cause injury e Failed parts can explode or cause other parts to explode when power is applied to inverters e Always wear a face shield and long sleeves when servicing inverters SHOCK HAZARD from testing e Turn Off welding power source and wire feeder or stop engine before making or changing me ter lead connections J N e Use at least one meter lead that has a self retaining spring clip such as an alligator clip e
20. WCL Workpiece Length WL See Section 5 1 for weld cable size Variations in welding processes and welding circuit resistance can affect apparent voltage at the welding arc Voltage sensing can improve welding performance by providing accurate Current Flow Path P gt feedback to the welding power source It is important to connect the voltage sensing lead as near to the weld as Large Weld Structure possible but not in the return current path Current Flow Path gt Ref 804 525 A OM 230 032 Page 23 5 3 Arranging Welding Cables To Reduce Welding Circuit Inductance Bad Better Best Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder Workpiece NGQOD O1 BB OWN The method used to arrange cables has a significant affect on welding properties As an example Accupulse and RMD welding processes can produce high welding circuit inductance depending on cable length and arrangement This can result in limited current rise during droplet transfer into the welding puddle The electrode sense lead is contained in the feeder control cable and automatically becomes enabled for all semi automatic processes The work sense lead connects to the Axcess welding power source 4 pin connector located above the negative output terminal This work sense lead automatically compensates for work cable voltage drop when connected
21. burns back to gun contact tip when using electrode negative straight polarity process Check to be sure that volt sense lead is connected to the work OM 230 032 Page 36 Notes OM 230 032 Page 37 SECTION 10 ELECTRICAL DIAGRAMS 717 S table NTN NTN Mm o N ce 1 1 1 H FERRITES TYP 3 PCS 55 es 3 ue sa iod c E gt pers lt RC1 Z TRANSMIT G gt SERIAL COMMUNICATION lt RC1 3 RECEIVE 8 gt BORD lt RC1 5 DONMON s Ro2 PL683 lt RC1 7 READY TO SEND DD KK RC2 4 lt RC1 8 CLEAR TO SEND P naiss ES J4 255 2 LE RC2 3 PSE KR DRC3 2 RECEIVE i 103 PROCESS CONTROL 14 432 X RC2 1 gt RC3 3 TRANSMIT 552 d z gt RC3 5 COMMON a 4 5 gt gt _ lt lt RC2 5 gt URBIS 44 65 8 X RC2 6 gt RE3 7 READY TO SEND M PLG3S gt RC3 8 CLEAR TO SEND W PL682 J5 PLG36 J amp PR C37 9 3 1 J10 FLGE1 lt 45 2 MOVE 228 FROM Te 42 9 ON PCM TO RG2 9 ON 235 m ESTOP BOARD 10 327 FOR ESTOP 237 COMBO J10 2 gt gt m e nop n 2 3 ADD FOR ESTOP p gt congo 42 4 pha m lt I PS TT ee AN ISSN 933555325589 Lv vy vw vy iv vy v Y Y iy 1 1 TNI SK Lis I I RR TH
22. drop Ref 804 528 A across the workpiece will not be measured correctly for the voltage feedback signal Voltage feedback to the welding power sources will not be correct at either sense lead and result in poor arc starts and arc quality OM 230 032 Page 26 B Better Setup GI F Current Flow Path gt Ref 804 529 A 1 Welding Power Source 6 Wire Feeder the welding power sources The most 2 Flectrode Cable accurate voltage sensing may not be 3 Feeder Cable 7 Workpiece achieved due to voltage drops in the workpiece This may require ki MO GROS This arrangement is a better setup for compensation in the welding parameters 5 Voltage Sensing Lead supporting separate voltage feedback to OM 230 032 Page 27 C Best Setup Par Current Flow Path gt 1 Welding Power Source 5 Voltage Sensing Lead 2 Electrode Cable 6 Wire Feeder 3 Feeder Cable 4 Work Cable 7 Workpiece Ref 804 530 A This arrangement is the best setup for proper voltage sensing at the workpiece Voltage feedback to the welding power sources will more accurate and result in reliable arc starts and better arc quality OM 230 032 Page 28 SECTION 6 OPERATION 6 1 Front Panel Switches Le H C C gt c Le N 2 x 2 c gt Le 3 Le J 2 H N 6 1 3 o o D o V o o Ref 803 669
23. falling e Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e 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 e 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 e Properly install and ground this equipment according to its Owner s Manual and national state and local codes F Indicates special instructions FV 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 e Always verify the supply ground check and be sure that input power cord
24. sized for Peak Amperage Apk for pulse welding applications 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 E For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 In pulse welding applications using inverter power sources peak currents can result in extreme voltage drops producing poor welding characteris tics with undersized cables A recommendation for weld cable size is a minimum of 2 0 for 300 ampere welding power sources and 4 0 for 450 ampere welding power sources when total cable length is less than 100 ft 30m OM 230 032 Page 22 5 2 Welding Circuit F Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder 7 Workpiece Her Standard Welding Circuit D O1 RON In pulse welding applications using inverter power sources cable resistance can result in less than satisfactory performance In most cases a welding circuit length of 50 ft 15 m or less will provide satisfactory performance with a standard welding circuit connection The length of a welding circuit is determined as follows Welding Circuit Electrode Cable Length ECL Work Cable Length
25. to the welding power source Do not coil excess cables Use cables that are the appropriate length for the application Whenever using long weld cables longer than 50 ft 15 m try to arrange positive and negative weld cables together to reduce the magnetic field surrounding the cables Avoid coupling the feeder and work sense leads with the weld cables Ref 804 526 A OM 230 032 Page 24 F Welding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensify 5 4 Using Multip le Welding Power Sources F R Current Flow Path gt Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder 7 Workpiece Each welding power source should have a separate work cable connection to the workpiece Do not stack or join work cables together at the workpiece This is very important for pulse welding applications It is important to connect the voltage sensing lead as near to the weld as possible but not in the return current path Connect voltage sensing lead at the end of the weld joint D O1 BAON The direction of the welding path should be away from the work cable connections Connect work clamp at the beginning of the weld joint Each welding gun should have its own source of shielding gas Use a separate shielding gas regulator and shielding gas connection for e
26. which if NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards 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 A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away m ELECTRIC SHOCK can kill 0 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 e Do not touch live electrical parts e 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 e Do not use AC output in damp areas if movement is confined or if there is a danger of
27. 032 Page 9 OM 230 032 Page 10 SECTION 3 DEFINITIONS 3 1 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 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 230 032 Page 11 1 Warning Watch Out There are symbol
28. 098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 e s Declares that this product Axcess 7 300 conforms to the following Directives and Standards European Contact Signature Directives Low Voltage Directive 73 23 EEC Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Machinery Directives 98 37EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Standards Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 August 2002 Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 2 1 Degrees of Protection Provided By Enclosures IP Code IEC 60529 Ed 2 1 Insulation Coordination For Equipment Within Low Voltage Systems Part 1 Principles Requirements And Tests IEC 60664 1 Ed 1 1 The product technical file is maintained by the responsible Business Unit s located at the manufacturing facility dec stat 1 07 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 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 A DANGER Indicates a hazardous situation
29. 2 3 3 Symbols And Definitions GI Direct Current Alternating A Amperage DC A Current AC V Voltage Output pa Circuit Breaker A Remote On O O O Off Positive Negative v Voltage Input Dn Arc Force Constant Voltage NA Inductance US rin Three Phase Static Frequency Con Gas Metal Arc m Increase 7 i Line Connection Welding GMAW ACY PI ao Rectifier U Rated No Load U Primary Volt Conventional X Duty Cvel 0 Voltage Average 1 ary vonage Load Voltage uy Set Degree Of Rated Welding H Z Hertz P Protection Current o BOGA Pulsed Single Phase SN Three Phase l iman Rated Maximum Supply Current tett Maximum Effective Supply Current Suitable for Some Hazardous Locations 3 4 Manufacturer s Rating Label MILLER ELECTRIC MFG CO uneegnen co 7 Miller AXCESS 300 CE SERIAL NO STOCK NO 907348 SERIAL TKODE EC 60974 1 EC 60974 1 1 EL 30A 15 5V 500A 39V 6 k x 20 60 100 U0 72 5 12 500 290 225 g RR bo ul 1P23C 2x10 60Hz 115V 10A x1009 www MillerWelds com ams EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 229908 A 229 908 A OM 230 032 Page 13 SECTION 4 INSTALLATION LF Appearance of actual unit may vary from unit shown in manual 4 1 Specifications Amperes In ao put At Ra
30. 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 e 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 e Les cables 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 qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer 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 piece soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la piece la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temp
31. 6621 Boot Generica vaga exea acr ACH a 2 16 4 PL site 163562 Light ind white lens a5 ebbe kaa r AT HSR Vd nnt a SAVN KAS TREE ERE 1 df cse Mei et ar 212717 xxx Nameplate Front si oclo ber RR Ae PM GL eee wade ele 1 TOU osi a 210865 Terminal Pwr Output Red 1 APA AN 210483 Bracket lift eye sese 1 200 BK a bai 210358 Bolt eye shld thd stem 500 13 X 1 500 1 san ea Deas 207980 Bus Bar output 1 Recommended Spare Parts 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 230 032 Page 47 Notes 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
32. AF 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 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 pr
33. C4 Off Indicates 25 volts dc is not present on process board PC4 3 4 On See Network Status Table in Section 9 4 Off See Network Status Table in Section 9 4 OM 230 032 Page 34 9 4 Network And Module Status LED s A Network Status LED s The following is a network status LED LED4 on the POM circuit board Status Diagnosis Off The circuit board is not on line with the network or there is no power applied to the circuit board Green The circuit board is operating normally and the on line connection is made with the network Flashing Green The circuit board is waiting for an on line connection to be made with the network Red The circuit board has encountered a communication link failure with the network Check DeviceNet cable connections Verify dip switch positions according to Sections 1 2 and 1 3 Replace circuit board if necessary B Module Status LED s The following is a module status LED LED3 on the POM circuit board Status Diagnosis Off There is no power applied to the circuit board or the board software is not executing its functions Green The circuit board is operating normally Flashing Red The circuit board has encountered a recoverable fault Wait or cycle power to clear fault Red The circuit board has encountered an unrecoverable fault OM 230 032 Page 35 9 5 Troubleshooting omes Trouble Remedy No weld
34. E Can high F 24 volts dc common G 24 volts dc H Motor voltage 40 volts dc common Ref 803 668 A Motor voltage 40 volts dc The remaining pins are not used OM 230 032 Page 19 4 10 Electrical Service Guide 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 NOTICE INCORRECT INPUT POWER can damage this welding power source This welding power source requires a CONTINUOUS supply of input power at rated frequency 10 and voltage 1096 Phase to ground voltage shall not exceed 10 of rated input voltage Do not use a genera tor with automatic idle device that idles engine when no load is sensed to supply input power to this welding power source gt Actual input voltage should not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available Three Phase 50 60 Hz Input Voltage 400 Input Amperes At Rated Output 10 4 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 Time Delay 2 10 Normal Operating 3 15 Min Input Conductor Size In AWG 4 14 Max Recommended Input Conductor Length In Feet Meters Ca Min Grounding Conductor Size In AWG 4 14 Reference 2005 National Electrical Code
35. ERE NER ER Ue EE a E ER EYE 30 SECTION 8 SAFETY PRECAUTIONS FOR SERVICING 31 8 1 Symbol Usage 22 31 8 2 Servicing Hazards 22 A Adik aa a NAA l s we 31 8 3 California Proposition 65 Warnings 32 8 4 EMF Information eR Im hr 32 TABLE OF CONTENTS SECTION 9 TROUBLESHOOTING curii riu nnn nmm rmm nn nnn 33 9 1 Removing Cover and Measuring Input Capacitor Voltage 33 9 2 Weld Process Board PC4 Diagnostic LED S 34 9 3 Diagnostic LED s On Process Board PC4 34 9 4 Network And Module Status LED s 2 22 2200 eee 35 9 51 Troubleshootingi s hte a NA toe seule Aa oa inh Nope a est le Saeed Aine Joga tia Aled 36 SECTION 10 ELECTRICAL DIAGRAMS Sl ads E S eee rmm han 38 SECTION 11 PARTS EIST Allie i RR EX eX pie E Sie eee ts 40 WARRANTY Declaration of Conformity for European Community CE Products F 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 20
36. LES GAZ peuvent tre dangereux Le soudage genere des fumees et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es e A 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 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 e 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 e 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 l
37. MAUON i kak iiec eee rd dee SAN a nete ments a oe du MG rco ta deer ow 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 215 OVMBOISSUUNISES audere erst tee ae scs abt sr durs oo tu Dl dd e den AO S 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 EMF 4 st vi Ea me KA PAK LA KA NAINA en ee E UBER DAP ENNA ELEM 9 SECTION 3 DEFINITIONS 5 522 x k inten pies sta a Obs aa k a ka 11 3 1 Manufacturers Warning Label Definitions 11 322 WEEE Fabel ee o deb Eb b A e eL e e b EE 12 3 3 Symbols And Definitions e III nnn 13 3 4 Manufacturers Rating Label mheis ie eec R A al A A SR ARRAY AR 13 SECTION 4 INSTALLATION iiei tru ban BAYAAN S Ta E ex ele SR R ee See 14 4 1 o 14 4 2 Dimensions And Weight ick aad U basta vi Sa NO st PN Y te Ka E dE E PRENDE 14 4 3 Duty Cycle And Overheating 15 4 45 Vol Amper C rves eee vaine te nn RERO RR a a B a a B laa Sa eR Ba 15 4 5 Selecting A Loc
38. Read instructions for test equipment OM 230 032 Page 31 FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e 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 MOVING PARTS can cause injury Keep away from moving parts such as fans e Keep away from pinch points such as drive rolls e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away from serv icing areas until consulting their doctor and the device manufacturer 8 3 California Proposition 65 Warnings A 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 A 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 reprod
39. Wire Feeder Gas Oylinder Gas Hose Network Feeder Cable Negative Weld Cable Workpiece 8 Voltage Sensing Lead Recommendedfor Accu pulse and RMD optional NGO O1 Bp ON F Positive voltage sensing lead is contained in the motor cable 9 Positive Weld Cable Ref 803 667 A Ref 801 915 A OM 230 032 Page 16 4 7 Rear Panel Receptacles And Supplementary Protectors 1 115V 10A AC Receptacle RC2 Receptacle supplies 60 Hz single phase power Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload If CB1 opens RC2 does not work CB2 protects the wirefeed motor from overload If CB2 opens the wirefeeder does not work F Press button to reset breaker If breaker continue to open contact a Factory Authorized Service Agent 4 Network Wire Feeder Receptacle RC1 Use receptacle to connect network feeder cable to power source see Section 4 6 Ref 803 668 A OM 230 032 Page 17 4 8 Connecting To Weld Terminals Niger F If using an electrode negative straight polarity process the volt sense lead must be connected to the work
40. a 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 provoquer des br lures dans les yeux et 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 soudage e 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 raux 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 230 032 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des reservoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de
41. ach welding gun Arc blow is the deflection of a welding arc from its normal path due to magnetic forces It will adversely affect the appearance of a weld cause excessive spatter and impair the quality of a weld Arc blow occurs primarily during the welding of steel or ferromagnetic metals Weld current will take the path of least resistance but not always the most direct path through the workpiece to the work lead connection The most intense magnet force will be around the arc due to a difference in resistance for the magnetic path in the base metal The work clamp connection is important and should be placed at the starting point of a weld It is recommended to have as short of an arc as possible so that there is less of an arc for the magnetic forces to control Conditions affecting the magnetic force acting on the arc vary so widely that the reference here is only about cabling connections and arc preferences Ref 804 527 A OM 230 032 Page 25 5 5 Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A Bad Setup Her Current Flow Path gt Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder ORUN 7 Workpiece This arrangement is a bad setup due to sensing leads being directly in the current flow path of the welding arc Interaction between welding circuits will affect voltage drop in the workpiece The voltage
42. act 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 not 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 w
43. al number required when ordering parts from your local distributor OM 230 032 Page 43 F Hardware is common and not available unless listed 7 803 422 B Figure 11 3 Top Tray Assembly Item Dia Par No Mkgs No Description Quantity Figure 11 3 Top Tray Assembly Fig 11 1 Item 4 cxt aw ROS ue 231928 Circuit Card Assy Aux Power 1 Lm 223439 Insulator circuit card Aux Power 1 cm 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 4 PC4 221277 Process Control Module 1 uev e ne tea cera a etree 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 8 ues Dope se E 210491 Panel Mtg Components Top 1 Nur 198122 Stand Off Support PC Card 250 w Post amp Lock 500 1 Recommended Spare Parts 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 230 032 Page 44 F Hardware is common and not available unless listed 8 803 672 A Figure 11 4 Rear Panel Assembly Item Dia Par No Mkgs No Description Quantity
44. anadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage 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 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 ENS 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
45. ations S slab S up A A A LUE 16 4 6 Gonnectiori Diagram s ae HES at BA hae hee Goa ST Bae eeu EDU Ko a 16 4 7 Rear Panel Receptacles And Supplementary Protectors 17 4 8 Connecting To Weld Terminals n 18 4 9 Network Wire Feeder Receptacle Functions 19 4 10 Electrical Service Guide 2 0 cose 8 A S S ta L eet Ae AE A tes 20 4 11 Gorinectirig Input Power 1 creo REA ramin aa A Saa a ba dla A EE MES 21 SECTION 5 RECOMMENDED SETUP PROCEDURES 22 5 1 Selecting Weld Cable Sizes 22 5 2 Welding Circuit ese ceo axa Sa kula hace a alk ala la AERA SERT teens Sedalia cae 23 5 3 Arranging Welding Cables To Reduce Welding Circuit Inductance 24 5 4 Using Multiple Welding Power Sources 25 5 5 Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs 26 SECTION 6 OPERATION 2 227752 72314 SS 0 2 S SES TSK Ska S T sS A K RR RGB alaska i ERRORES ER 29 6 1s Front Panel Switches onset AS NE e ha EE ERES 29 6 2 Options take ainda a asa Sak O 29 SECTION 7 MAINTENANCE ooccccccccccn eee 30 Tels Routine Maintenance iL mre Im E m REN Nee RED Gm ET t k ad 30 7 2 BloWing O t Insid OF Unit uc Sig
46. cessories e 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 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 a 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 J e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards G N MOVING PARTS can cause injury e 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 e Do not point gun toward any part of the body other people or any metal when threading welding wire PAL STATIC ESD can damage PC boards Pan MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place NU e Have only qualified persons remove doors panels covers or guards for maint
47. e 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 e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et 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 e Le couvercle 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 le
48. e of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes 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 e 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 near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing 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 sla
49. easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And 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 a che US A 6 besos eren fo exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Staridard 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 mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 131 Symbols age rt iet te oett de vet eie rd nue exe Ae 1 1 2 Are Welding Hazards tion hee vetet er ge xe e tr x RU ex sex ER 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings HH 4 1 5 Principal Safety Standards 4 1 6 HEME INfOR
50. ed m U P m auus 196343 Resistors W Leads 8 Plug 1 fenis bse C tm Hoo eased AS 196840 Insulator Resistors Interface Board 1 O Re ue saute 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 1 most acces eie ares 196514 Gasket Inductor Mounting 2 Abad nahh EROS LM napaka 196512 Bracket Inductor Mounting 2 M oed rtt LAE 196330 Heat Sink Power Module 1 o re 2 nes 196345 Coil Inductor Pre regulator 1 dos AA 196588 Baffle Foam Rubber Lower 1 Lane as acea cast eek Qr ead d 196365 Plugs w Leads Fan d Em 199136 Plugs w Leads PC2 To PC1 1 36 PO 216192 Circuit Card Assy Control Inverter 400A 1 SCC 204846 Insulator Screw 4 d gelb an 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 4 Recommended Spare Parts 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 seri
51. elding Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not 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 traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 230 032 Page 2 C EEI 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 fre
52. enance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e 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 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 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 e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure th
53. er les mains apres manipu lation OM 230 032 Page 8 Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A 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 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 tilly 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 C
54. euv re est ex cuter dans un endroit sir 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 43 circuits imprim s SIS So N e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures 3 a e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 230 032 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geantle fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures 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 pro
55. g 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 equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A 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 ac
56. ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e 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 e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal
57. iation 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 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 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 230 032 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproduc
58. ice less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from
59. ing 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 9 TROUBLESHOOTING 9 1 Removing Cover and Measuring Input Capacitor Voltage C H lt shein Turn Off welding power source and A 900 Volts dc can be present on the capacitor bus and disconnect input power significant DC voltage can remain on capacitors after unit is Off Always check the voltage on both Remove cover inverter assemblies as shown to be sure the input 1 Interconnect Board PC2 capacitors have discharged before working on unit P 9 g 2 Voltmeter Measure the dc voltage across the bus terminal and bus terminal on PC2 as shown until voltage drops to near 0 zero volts Measure input capacitor voltage on inverter assembly before proceeding 3 Typical Bleeder Resistor An example of a typical bleeder resistor is shown on this page Proceed with job inside unit Reinstall cover when finished lead to left bus terminal lead to right bus terminal Typical Bleeder Resistor 25 to 1000 ohm 5 watt resistor y E 3116 AWG 1000 volts dc insulation rating approx 3 in 76 mm leads 802 985 Ref 803 670 A OM 230 032 Page 33 9 2
60. input conductors L1 L2 and L3 to disconnect device line terminals 8 Over Current Protection Select type and size of over current protec tion using Section 4 10 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position OM 230 032 Page 21 SECTION 5 RECOMMENDED SETUP PROCEDURES 5 1 Selecting Weld 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 Weld Cable Size and Total Cable Copper Length in Weld Circuit e Not Exceeding a 350 ft 400 ft 150 ft 200 ft 250 ft 300 ft 100 ft 30 m or Less 45m 60m 70m 90 m pang B Weld Output Terminals A Turn off power before 10 60 60 100 connecting lo weld Panes Duty Duty 10 10096 Duty Cycle output terminals p Cycle Cycle A Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60
61. is 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 230 032 Page 3 1 4 California Proposition 65 Warnings A 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 A 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 249 1 from Global Engineering Documents 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 Assoc
62. 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 surchaut fement ou un incendie Avant de commencer le soudage v rifier 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 soigneusement avec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e 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 soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un 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 F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple
63. lisation 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 metalliques 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 F Indique des instructions sp cifiques e PF Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y 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
64. 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 A Only qualified persons should test maintain and repair this unit A During servicing keep everybody especially children away e ELECTRIC SHOCK can kill e Do not touch live electrical parts e Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from re ceptacle or stop engine before servicing unless the procedure spe cifically requires an energized unit e Insulate yourself from ground by standing or working on dry insulat ing mats big enough to prevent contact with the ground e Do not leave live unit unattended e lf this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job e When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free e Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Troubleshooting Section be fore touching any parts P STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling
65. n Quantity Figure 11 1 Main Assembly ak UOS AERE S 210492 Cover Top 1 bas Laci Mas 212543 Xfmr Control Toroidal 665 VAC Pri 1900 VA 60 Hz 1 Lx PANA ts M anced 210481 Plate Mtg Toroid XfMr 1 Usted AA Fig 11 3 Top Tray Assembly 1 r IM 1 214597 Windtunnel LH w Components Fig 11 2 1 IM 1 222958 Windtunnel RH w Components Fig 11 2 1 pee O tr EEEE Fig 11 4 Rear Panel Assembly 1 Jer adi CLAIR IAE dS 230260 Panel Side W Insulator 2 E p rie 2104829 Base a MEL LEE 1 E DIE 220200 Assembly Filter Primary 1 vss NO ADS aai 182918 Transducer Current 400A Module Supply V 15V 1 nab dust bak 220377 Bracket Input Filter Top 1 2 RR 1 Boedo tau A 204846 Insulator Screw 1 13 PC14 185697 Circuit Card Assy Input Filler 1 mad akan 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 td dd TEA 220376 Bracket Input Filter Bottom 1 O as 213372 Filter Assy Secondary
66. oing 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 A 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 2 2 Dangers relatifs au soudage l arc A 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 matiere 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 A Seul un personnel
67. or 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 setting and use grounding and shielding to minimize the possibility of interference READ INSTRUCTIONS e Use Testing Booklet Part No 150 853 when servicing this unit e Consult the Owner s Manual for welding safety precautions e Use only genuine replacement parts from the manufacturer For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 1 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 go
68. 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 c bles 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 dinterferences 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 c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconna t 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 reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres problemes de procr ation Se lav
69. orks 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
70. output completely inoperative Place line disconnect in On position see Section 4 11 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 11 Check for proper input power connections see Section 4 11 No weld output meter display on with no error displayed Check to see if the contactor indicator light is lit when contactor line is asserted on Erratic or improper weld output with no errors displayed Use proper size and type of weld cable see Section 5 1 Clean and tighten all weld connections No 115 volts AC at the duplex receptacle Reset supplementary protector CB1 Wire does not feed Check supplementary protector CB2 and reset if necessary Check motor control cable connections Wire feeds erratically Readjust hub tension Readjust drive roll pressure Clean or replace dirty or worn drive rolls Remove weld spatter around the nozzle opening Replace contact tip or liner See gun Owner s Manual Check motor control cable connections Wire feeds as soon as power is supplied Check gun trigger See gun Owner s Manual Wire stubbing on low end using a constant current power source Increase output setting of the power source Check voltage sense lead connection clean and tighten if necessary Gas does not flow or does not stop flow ing wire feeds Check gas valve and flow meter Wire
71. qualifi est autoris a installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir a distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut Na 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 impropre constitue un danger 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 piece 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 o 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 uti
72. r des blessures dans les yeux e 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 e 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 Fermerl 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 distance e 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 ou 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 gee elle peut exploser Du fait que les bouteilles de gaz font normalement parti
73. rage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty 60 Duty Cycle At 300 Amperes 6 Minutes Welding 5350 68 4 Minutes Resting Overheating Hug x LS 0 gt gt las gt Minutes OR AN gt Reduce Duty Cycle duty1 4 95 230 226 A 4 4 Volt Ampere Curves CV MODE Volt ampere curves show minimum and maximum voltage and amperage output capabilities of unit Curves of other settings fall between curves shown F This volt ampere curve represents the dynamic output of the unit with a static load va curve1 4 95 OM 230 032 Page 15 4 5 Selecting A Location p N Movement Tipping A Do not move or operate unit where it could tip Location A Special installation may be required where gasoline or volatile A Do not stack units Beware of liquids are present see NEC Article 511 or CEC Section 20 tipping 1 Lifting Forks 3 Use lifting forks to move unit Extend forks beyond opposite side INPUT SERIAL NO of unit STOCK NO 2 Hand Cart VOLTS Paan AMPERES Use cart or similar device to move ad unit PHASE 3 Rating Label Use rating label to determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply loc 2 3 96 Ref 803 667 A Welding Power Source
74. rs Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 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 HF Units 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 MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp S
75. s Disconnect input plug or power before working on machine possible hazards as shown by the 2 Electric shock from wiring can kill 4 Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes after power is turned off before working on unit OR Check input capacitor voltage and be sure it is near O before touching any parts When power is applied failed parts 4 04 can explode or cause other parts to explode Flying pieces of parts can cause injury Always wear a face shield when servicing unit Always wear long sleeves and button your collar when servicing unit After taking proper precautions as shown connect power to unit 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Falling equipment can cause injury and damage to unit 3 Always lift and support unit using both eye bolts Keep angle of lifting device less than 60 degrees 4 Use a proper cart to move unit 5 Do not use one eye bolt to lift or support unit 1 96 3 2 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 230 032 Page 1
76. s OM 230 032 Page 29 SECTION 7 MAINTENANCE 7 1 Routine Maintenance GI ne A Disconnect power F Maintain more often mo o before maintaining during severe conditions 7 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent e Every 3 x Unreadable Labels Weld Terminals Damaged Gas Hose X Weld Cables Months MA Cords Gun Cables Every 6 Months O Drive Rolls O Inside Unit 7 2 Blowing Out Inside Of Unit GI A Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown Ref 803 667 A OM 230 032 Page 30 SECTION 8 SAFETY PRECAUTIONS FOR SERVICING A Protect yourself and others from injury read and follow these precautions 8 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 8 2 Servicing Hazards A The symbols shown below are used throughout this
77. s cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pieces 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 facon 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 e Ne pas raccorder plus d une electrode ou plus d un cable de masse une m me borne de sortie de soudage OM 230 032 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation e 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 e Ne pas toucher aux pieces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures A LES FUM ES ET
78. s 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 e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e 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 l anneau 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 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 ue 1 L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT WA e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal hd Qon 4 e R auire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage ei les yeux e Affiter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette mano
79. ssembly Item Dia Part No Mkgs No Description Quantity Figure 11 5 Front Panel Assembly Fig 11 1 Item 14 E E S1 itn 207456 Switch Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg 1 RUP UPON Tas 207895 Insulator Switch Power 1 X mm 211475 Plate front panel 1 Lud vac POTI se 208071 Circuit Card Assy ISO COMM 1 MOOD os es FM 196313 Fan Muffin 115V 50 60 Hz 3000 Rpm 6 378 Mig Holes 1 6 C6 C7 C8 206878 Capacitor ASSY i 3 uv dass fusce pns E 213102 Choke Common Mode w Leads 2 O ME Lee 216965 Cover Connector D sub 9 skt Female w Chain 1 CLE EIE 216966 Cover Connector D sub 9 pin Male w Chain 1 sago MOL iis S BOB us 214664 Receptacle Common Mode Choke 1 stag MA st to Ra ott 210866 Terminal Pwr Output Black 1 Au vI C an eh 210476 Panel Front 2 1 CIS HOR 219843 Label Volt Sense wordless 1 OM 230 032 Page 46 No Mkgs No Description Quantity Figure 11 5 Front Panel Assembly Continued 14 207979 Box Louver 1 152 bia 18
80. tection 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 tiliser 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 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
81. ted Rated Wire Feed Wire pen Load Output PE Welding Hs Speed Diameter Circuit Volt 60 Hz pi ME Output 9 Range Range De Three Phase 400V 225 A Sindara 10 4 7 2 6 9 Three E mt nda 50 1400 030 062 in s 0 2 0 04 Phase 7 j ipm 0 8 1 6 mm Duty 1 3 35 6 mpm Cycle While idling Input amperage fluctuates while idling and is always less than one Ampere Use one Ampere for power efficiency calculations Wire feed speed ranges are for GMAW welding While pulse welding wire feed speed ranges may be more limited 4 2 Dimensions And Weight Hole Layout Dimensions E Le A NS A 17 3 32 in 434 mm d a B 17 3 8 in 441 mm C 19 3 32 in 485 mm D 16 3 32 in 409 mm c B E 1 2in 13 mm Weight FT if 112 Ib 51 kg Net 134 Ib 61 kg Ship L D i 17 3 32 in 434 mm 22 1 2 in 572 mm 2 Ref 803 667 A OM 230 032 Page 14 4 3 Duty Cycle And Overheating 500 400 300 250 3 PHASE 200 OPERATION WELDING AMPERES 150 100 15 100 Duty Cycle At 225 Amperes J Continuous Welding 20 25 30 40 DUTY CYCLE 50 60 70 80 90 100 Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce ampe
82. tive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face 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 Regional 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 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 g
83. uctive harm Wash hands after handling 8 4 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 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 230 032 Page 32 OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit 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 install test and service H F producing units e The user is responsible f

Miller Electric Axcess 300 User's Manual

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