Miller Electric 22A Welder User Manual
Contents
1. 12 3 9 Motor Start Burniback Control 2244 RR REA RERO ER RR RU E E de dd 13 3 10 Installing Wire Guide And Drive 14 3 11 Installing And Threading Welding Wire 15 SECTION 4 OPERATION xix ose s mex bu mE ME RE qx SEES EE SUE NE 16 4 1 Front Panel Controls x um e Rr brat E RC Et e Rn o eee 16 4 2 Optional Side Panel 17 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 17 9 1 Routine boc De t enr SO oc ue bes ed ac de 17 5 2 Overload Protecuon s uos auc es e RC RU Cn o Fn mener c Le Race C ac ab aye IE 18 5 9 MOUDIGSNOOUNG auus ested en eor Ce een eC Sube e Oe om te e tt bb dns eee awe awe ane oe ae x 18 SECTION 6 ELECTRICAL 19 SECTION 7 PARTS EIST ccc 2 iem nimes EN ete eE ea titre Certes 20 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch2. x N d x dd PLG1 AA A Pb FAR AT CONNECT 3 35 45 LL LL _ 222 211 TO LEAD 5 5 lt 1 4 99 Bas 38 OF RC9 SEE NOTE 3 PLG45 PLG42 METER lt RC1 10 SENSE 0 00 1 e S4 PREFLOW POSTFLOW gt lt ins Bi ro a WIRE 98 2 295 _ RC16 PLG16 ok 1 WAS PLUGGED DRIVE HOUSING Q 7X2 T RASE BOARD RC3 21 INTO RC3 1 4 4 lt RC16 2 AE 32 27 53 25 2 gt gt 2 PREFLOW POSTFLOW METER OPTION PLG33 PLGS SPOT OPTION ESE ey np DES E zl t ipmen Equ Feeder With Opti ire For W ircuit Diagram Figure 6 1 C OM 193 472 Page 19 SECTION 7 PARTS LIST 5 Hardware is common and not available unless listed Figure 7 2 amp Figure 7 3 Figure 7 1 Main Assembly 802 358 OM 193 472 Page 20 Item Diagram Part No marking No Description Quantity Figure 7 1 Main Assembly Eo pep E 089 899 Wt gere 1 P METERS 198 650 WRAPPER eee ttes ira Ne dE qu died dto E 1 ee 126 979 BUMPER d ien n ace don D dcin ee 1 um 134 464 LABEL warning electric 5 1 EC run bees 072 094 amp SPINDLE ASSEMBLY consisting of 1
3. ose tete tee I iid PLG15 115 092 CONNEGTOR amp SOCKETS Ever 71 NEAN PLG16 131 055 CONNECTOR amp SOCKETS 1 OM 193 472 Page 21 Item Diagram Part No marking No Description Quantity Figure 7 1 Main Assembly Continued EIER 115 443 STAND OFF 6 32 750 19 2 EOS sale 197328 CASE ASSEMBLY gt bat Etsi ber bl ks 1 RMS Bu dre duos Utt 183 914 BLANK snap in 1 250 mtg hole 1 d LAC Scip ceca a ad dado NAMEPLATE order by model and serial number 1 MU CETERO 097 924 KNOB POINTE ke ae eee ete CRUS UK ea Be 1 MN CERNERET 097 924 KNOB pointer 1 37 RC2 048 282 RECEPTACLE WSOCKETS Lans iii sentent 1 Mo er HORN 196 956 LABEL warning electric shock and pinch 1 PPP 72 PLATE NSUlalOn be Cd Aie addi e 1 Fig 7 2 amp 7 3 WIRE DRIVE 5 1 laps P 188 149 GUIDE wire inlet consisting of 4 drive roll 1 082 050 LINER monocoil inlet wire 1 POE 082 036 GUIDE w
4. Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants procr ation Se laver les mains apr s manipulation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr
5. There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away m ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts 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 grou
6. 1 P TE 600 797 GABLE port No 18 9 6 ioo zie Ee RE LEX RP RR 1 uibem PLG41 131 204 HOUSING PLUG amp SKTS cs 26 M1 193 188 MOTOR gear 24VDC 146RPM consisting of 1 136 745 BRUSH amp SPRING ASSEMBLY 2 27 651 228 036 VALVE 24VAC 1way 750 14 thd 2mm orf 100PSI 1 haat PLG1 115 093 CONNECTOR amp SOCKETS 522 p i ative detente PLG3 115 092 CONNECTOR amp SOCKETS 1 RUN PLG4 115091 CONNECTOR amp SOCKETS 1 nibo e PLG5 130203 CONNECTOR amp SOCKETS 1 20 Hes 073 562 POTENTIOMETER C sltd sft1 T 2W 10K ohm 1 29 R50 4035 897 POTENTIOMETER C sltd sft1 T 2W 1K linear 1 30 ar 211476 SWITCH tol SPTT GA 125VAU su PEE E Ere doe e ce de Bee 1 31 y DO uc 134 847 SWITCH tgl SPDT 15A 125VAC 1 187 577 COVER opening meter 1 UAE DL LES 133 644 FRAME snap in switch rocker 1 32 PC2 186 268 CIRCUIT CARD meter consisting of 1 es dtes LODI 181 295 METER digitale uns itecto AOI rao e
7. 90605 939 WASHER ss ean dope aedes tae Y 604 645 NUT 375 32 x 56 hex 1 Re aa 70 210 408 CIRCUIT CARD 5 5 1 194 310 BRACKET mounting 1 PR 097 132 STAND OFF 6 32 375 lg 250 hex 2 4093 55T s KNOB pdd dde 140 789 SWITCH eo i ade eec 4210 436 LABEL indicator run in 1 A ee 193 719 BRACKET mounting receptacle 1 gal eM E 115 093 HOUSING PLUG amp SOCKETS 1 RE TT 131 059 HOUSING PLUG amp SOCKETS sus sise EE ERE ERR buried le ea hot 6115 091 HOUSING PLUG amp SOCKETS eb eee ees 1 guided mA E 135 5931 HOUSING PLUG amp SOCKETS Be one 048 282 HOUSING PLUG amp SOCKETS 1 AO 211 989 FITTING w screen ns 1 When ordering a component originally displaying a precautionary label the label should also be ordered OPTIONAL OPTIONAL I
8. CONNECTOR amp PINS 1 PLG33 115092 CONNECTOR amp SOCKETS 1 eee PLG51 6 115 091 CONNECTOR amp SOCKETS 1 19 CB1 161 078 CIRCUIT BREAKER man reset 1P 7A 250VAC 1 20 9132 111 997 SWITCH rocker SPST 10A 250VAC 1 RE TT 0138 044 S TRAIN RELIEF gt ad aud ar aoc dt nce de ordre tte ets 1 DD piatto is 126 693s CABLE SENSING 1510 ES Rc t asco ec e rtc ea reiten 1 m c PETERS 220 805 NUT 750 14 1 48hex 41h nyl 1 NEED 115104 CONNECTOR clamp cable 500 1 ba acad Uta 010325 BUSHING strain relief 840 ID X 875 mtg hole used with 24A 1 WE ades fori d 192 525 CABLE power 10ft 4in 18ga 3c consisting of 11ft 143 922 CONNECTOR circ coc clamp 1 TEE 192271 CABLE DOMINO over v Ee eR EN PLG9 141 162 HOUSING PLUG 1 PLG7 115 093 HOUSING PLUG amp SKTS SE 192 526 CABLE power 108 4in 16ga 8c used with 24A consisting of 111 079 739 CONNECTOR circ coc clamp
9. other reproductive harm 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 OM 193 472 Page 3 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 ihs 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 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 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 i
10. quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil 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 distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiler ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement 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 Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce
11. 2 Check gun trigger connection at wire feeder Check gun trigger leads and trigger switch See gun Owner s Manual Run In speed is set to minimum Normal setting is 50 percent Have Factory Authorized Service Agent check drive motor and control board PC1 Wire feeds erratically Readjust hub tension and drive roll pressure see Section 3 11 Use correct size drive roll see Parts List Clean or replace dirty or worn drive roll see Section 3 10 Remove weld spatter around nozzle opening Replace contact tip or liner See gun Owner s Manual Have Factory Authorized Service Agent check drive motor and control board PC1 Wire feeds when Jog switch is pressed but not when gun trigger is pressed Check gun trigger connection at wire feeder Check gun trigger leads and trigger switch See gun Owner s Manual Wire feeds as soon as power is applied Check gun trigger See gun Owner s Manual Wire does not feed until trigger is pressed but continues to feed after trig ger is released Check for short between gun trigger leads and weld cable Repair or replace gun trigger leads Gas valve rattles loudly and wire feeds slowly or erratically Check for short between gun trigger leads and weld cable Repair or replace gun trigger leads Gas does not flow wire feeds Check gas valve and flowmeter OM 193 472 Page 18 WARNING Do not touch live electrical
12. 20 1 MEC REEF 172 391 HOUSING adapter gun feeder 1 Lloris 048 449 WASHER shldr 363 OD x 194 ID 703 1 124778 KNOB T 2 000 bar w 312 18 1 00019 1 le 605 308 RING ring ext 500 1 079 625 WASHER wave 500 ID x 4750 OD x 015thk 1 Sud Smart nucis 121 271 SCREW 250 20 500 soc hd 1 Ded ass du dS 172 076 CARRIER drive roll w components 24 pitch 1 seid d pae iint a 092 865 tine ho 1 I RENTRER 192 874 INSULATOR motor drive 1 See Table 7 1 For 8 Drive Roll amp Wire Guide Kits 802 019 A Figure 7 2 Drive Assembly Wire 2 Drive Roll 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 193 472 Page 23 Item Diagram Part No marking No Description Quantity Figure 7 3 Drive Assembly Wire 4 Drive Roll Fig 7 1 Item 40 mr 602 009 SCREW 250 20 x 1 250 soc hdhexgr8 4 172 075 CARRIER drive roll w
13. 3 m me temps cause de la pr sence d une tension vide doubl e E UNE DECHARGE ELECTRIQUE peut e N utiiser qu un mat riel en bon tat R parer ou remplacer sur le 9 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut Porter un harnais de s curit si l on doit travailler au dessus du sol ace dents e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est aedes R Sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique a la terre de mani re incorrecte ou impropre constitue un danger Ne pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ce
14. parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install 210 430 A SECTION 6 ELECTRICAL DIAGRAM ELECTRIC SHOCK HAZARD use or service this unit OPTIONAL REMOVE JUMPERS RC3 4 gt RC2 NOTES 1 ON POWER SOURCES THAT SUPPORT VOLTAGE FEEDBACK AND HAVE THE METER OPTION vfdbk MODE CONNECT PLG41 TO PLG42 PLG43 HANGS FREE 2 ON POWER SOURCES THAT SUPPORT VOLTAGE FEEDBACK vfdbk AND HAVE BOTH THE METER OPTION AND RUN IN CONTROL CONNECT RC44 TO AND CONNECT lt RC1 5 1 gt gt 8 5 PLG41 PLG44 TO PLG42 AND PLG71 TO RC71 RUN IN BOARD TO i TRIGGER 3 ON POWER SOURCES THAT DO NOT SUPPORT VOLTAGE FEEDBACK PREFLOW POSTFLOW lt RC1 2 RC4 10 gt gt 2 gt gt I lt 2 CONNECTION SENSE LEAD MODE CONNECT PLG43 TO PLG42 PLG41 HANGS FREE AND OR 4 POWER SOURCES THAT DO NOT SUPPORT VOLTAGE FEEDBACK METER E 2 REED SWITCH 15 REQUIRED FOR RUN IN OPTION gt gt RED a m un lt 1 3 WIRE awe 4 RUN IN CONTROL lt RC1 6 MOTOR MOTOR TO MOTOR 45 22 54 OPTION 2 ROLL 4 ROL CONTROL 33 CONNECT 2 lt lt 1 MOTOR CONTROL 25 ALK RED BOARD RC1 5 gt gt 5 PLUG THAT BOARD 2 gt gt gt gt 2 gt 2 WAS PLUGGED JOG PLG4 RC4 2 RCI lt RC1 PL
15. welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby ou E FLYING METAL 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 OM 193 472 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in u
16. 1 lb ane Rec 168 590 BUSHING insulating 2 TE re 072 010 WASHER shldr 316 ID x 812 OD x 187thk 2 hap O edie SAUT 124778 KNOB T 2 000 bar w 312 18 1 000lg 1 A ene ee 079 625 WASHER wave 500 ID x 750 OD x 015thk 2 ie 092 SOS scil setate 1 172 077 CARRIER drive roll keyed 24 pitch 1 M E 121 271 SCREW 250 20 500 soc hd 1 To CD 192 875 INSULATOR motor drive 1 See Tabe 7 2 For Drive Roll amp Wire Guide Kits 802 018 A Figure 7 3 Drive Assembly Wire 4 Drive Roll 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 193 472 Page 24 Table 7 1 Drive Roll And Wire Guide Kits 2 Drive Roll Base selection of drive rolls upon the following recommended usages V Grooved rolls for hard wire U Grooved rolls for soft and soft shelled cored wires U Cogged rolls for extremely soft shelled wires usually hard surfacing types V Knurled rolls for hard shelled cored wires Drive roll types may be mixed to suit particular requireme
17. G1 5 JO S2B RENTE RC3 PLG3 90 i RCA PLGA RC4 5 gt gt 6 gt gt START COMMAND RC5 PLG5 gt gt 9 9 RCS RC9 PLG7 RC7 43 que a lt 25 lt a cH ee m 55 COMMON cw 22 44 WIRE t zu WAT GEN 39 RC4 7 gt MOTOR B lt lt B lt lt 5 SPEED CONTROL x BOARD RC4 2 2 ee 69 5 REMOTE VOLTAGE 5 6 gt 10 gt gt 10 FLUG THAT SEE MS CONTROL ON RC5 7 gt gt 2 O s gt gt s Wir ane amp 53M adiu p e 4 P RC5 5 gt P DP d L 3 RT 5 AR 67 54 99 c lt 2 M5 RC5 8 gt c BTE c oc ecc orav 68 RC5 1 gt OPTIONAL REED SWITCH SEE NOTE 4 au Res d MEI LAT i o HOLD a IL 1 gt lt lt 76 5 NOTE ROUTE WELD CABLE gt 4 gt 2 RC76 PLG76 D e 69 55 THROUCH REED SWITCH lt RC76 6 RC 1 PLG71 4 4 ul ASSEMBLY L 4 RC7D PLG7O __ 3 9 9 2 E po ccc cC M E MMC 5 ON E Voyy o PO 7 xh AN H s 5 S CONTACTOR ALU 1 S 2 ce F 5 5 mE 83 START COMMAND anre 5 CONTROL 3 sms REDE ELO MEO BOARD 6 gt 4 COMMON ATATA 82 TRIGGER 3 2 1 SEE NOTE 1
18. LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI 249 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 vo tre casque e 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 e Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincell
19. N 22A STANDARD IN 24A 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 193 472 Page 22 Item Diagram Part No marking No Description Quantity Figure 7 2 Drive Assembly Wire 2 Drive Roll Fig 7 1 Item 40 T E E 602 009 SCREW 250 20 x 1 250 soc hd hex gr 8 1 MT 172 075 CARRIER drive roll w component 24 pitch 1 054 263 SCREW thumb stl 250 20 500 1 bad TERRE ies 010 224 PIN spring 187 1 000 2 bem rende tes 1 rod dla 160 072 SPACE GOAN SEE Mn MR neue Moa CR Ld Rc dde 1 RN c MOON 089 562 FASTENER pinned 1 Ch 085 244 WASHER cupped stl 328 ID x 812 OD 125 1 UP 089 477 SPRING cprsn 770 OD x 105 wire x 1 225 1 CURTIS 085 243 KNOB adjustment tension 1 5 10 iret 165 071 LEVER mtg pressure Qear es 1 ME 151 828 PIN cotter hair 054 750 2 NOTER 079634 PIN DIFIQO ete ici ea Cyan ios 1 144172 FITTING hose brs barbed m 3 16 tbg x 250
20. OM 193 472N 2006 05 Miller p MIG GMAW Welding Flux Cored FCAW Welding Description ES Wire Feeder 22 24 OWNER S MANUAL File MIG GMAW a Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir BL El Her This Owner s Manual 15 designed to help you get the most out of your Miller products Please take time to read the Safety precautions They boleu Ie ete jue ere ex e every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick and easy With Miller you can count on years MI 00012000 of reliable service with proper maintenance And if f
21. ONE REM 058 427 RING retaining spool 1 Wc AN 180 572 SHAFT spool support 1 wu re 010 233 SPRING cprsn 970 OD x 120 wire 1 250 1 GE sie das 057 971 WASHER flat stl keyed 1 500dia x 125thk 1 uc ER 010 191 WASHER fbr 656 ID x 1 500 OD x 125thk 2 o PEE 058 628 WASHER brake 2 255 cn 058428 face AWB SPOON SSL RS Ta ni basura bae qr lee Su 1 der es ns 135 205 NUT stl slflkg hex reg 625 11 w nylon insert 1 Se ee 197 401 5 BASE un nn duel eee 1 db Acs Io uate 134 306 FOOT rbr 1 250dia x 1 375 high 4 PCI 207272 CIRCUIT CARD motor speed control 1 gt 134201 STAND OFF SUPPORT card 5 1 sa 191 191 WIRE GUIDE amp Ses ess he e Re cede eat 1 18 2 186 297 CIRCUIT CARD iuret eta dnm drm ccce rect tee 1 de 098 691 STAND OFF 6 32 x 500 1 4115093 CONNECTOR amp SOCKETS PLG3 135 409
22. Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keepcables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body B m m 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 Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som 3 05 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes EALA Ce groupe de symboles signifie Avertissement Attention Risques 2 1 4 Symboles utilis s Symbole graphique d avertissement Attention Cette pro c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints Indique un message de s curit particulier d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer gt Signifie NOTE n est pas relatif la s c
23. PAREIL 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 L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s 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 PC DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geantle fil de soudage lm 2 4 Proposition californienne 65 Avertissements
24. Welding Power Source With 24 VAC Power CV Welding Power Source Without 24 VAC Power 115 Volts AC 24 Volts AC Power Adapter 14 Pin Control Cord Weld Cable Required Work xN _ 115 Contactor 3 5 Gas Hose With 5 8 18 Right hand Thread Fittings Customer Supplied C7 Shielding gas pressure not to exceed 100 PSI 689 kPa 2 14 Pin Plug PLG2 Use plug to make connection to welding power source 3 Optional Volt Sense Lead Part Of Meter Option Connect to work 4 Power Switch Tools Needed J 8 5 8 11 16 in 802 349 A OM 193 472 Page 10 3 6 14 Pin Plug Information A remore 14 Pin Pin Information 24 volts ac with respect to pin G Contact closure to A completes 24 volts ac contactor control circuit Circuit common for 24 volts AC circuit 10 volts dc output to remote control with respect to pin D Remote control circuit common to 10 volts dc input command signal from remote control with respect to pin D Current feedback 0 to 10 volts dc 1 V 100 A Voltage feedback 0 to 10 volts dc 1 V 10 arc volts IIn M ou gt The remaining pins are not used Ref S 0004 A 3 7 Connecting Welding Gun And Weld Cable 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob insert gun into block Position outlet wire guide as close as possible to drive rolls without touching Tighte
25. aims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2006 Miller Electric Mfg Co 2006 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller
26. and boxes to store move or ship PC boards 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 3 1 4 California Proposition 65 Warnings STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts H F RADIATION can cause interference e High frequency can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the instal
27. ar n c acr d er Dot a a bd ed DAC Ee V d M ic 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS USES free a dnce o ee Dalee aad 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 7 2 5 Principales normes de S curit de Sox exa iae s Rex dant epe pp ar an 8 2 6 Information Rex coeds REX ERES EXARSIT ee RUE ei 8 SECTIONS INSTALLATION 2 3 m beso rue EEG IEEE Gehan RACE RUE dues etes 9 SM SD CIICAIOAS DEDE 9 Jo ole SSIesor alae ea ote ra Ca cd etapa dore ama des 9 3 9 Gun Becomriendatiol Table Road det aude a ON dass oa 10 3 4 Equipment Connection Diagrams 10 3 5 14 Pin Plug Shielding Gas And Optional Volt Sense Lead 10 3 6 T4 Pn Plug Informaltoll 35954 a ERG an eed ee LEARN IN RE PRSE REN EE RR 11 3 7 Connecting Welding Gun And Weld 11 3 8 Optional Meter Circuit Board Settings
28. component 24 pitch 4 TP 160 072 SPACER do edt dee o ER deer M E e D dea 4 TU OP 054 263 SCREW thumb stl 250 20 500 2 PEE o 010 224 PIN spring CS 187 x 1 000 2 FiO nate 089 562 S FASTENER pinned du 2 mui quidam dads 085 244 WASHER cupped stl 328 ID x 812 OD 125 2 GR 089 477 SPRING cprsn 770 OD x 105 wire x 1 225 2 eee 085 243 KNOB adjustment tension 2 zi dU in 166 071 LEVER mtg pressure gear 1 019694 PINS DINGO t arn eodd e eed hri Rea 1 EK LLORAR 151 828 PIN cotter hair 054 750 2 166 338 LEVER mtg pressure gear 1 605 308 RING 500 5 222 RES EI RE e 1 bs WD 187 325 INSULATOR drive assembly 1 cer ie 144 172 FITTING hose brs barbed m 3 16 tbg x 250 20 1 T rM PERPE 166 337 HOUSING adapter gun feeder
29. conduites gel es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque e Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes e Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux pw re 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 OM 193 472 Page 6 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser l
30. de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que 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 Lecouvercle du d tendeur doit toujours tre en place sauf lors que 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 suf fisamment de personnes pour soulever et d placer les bouteil les e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 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 produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L AP
31. dental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2006 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 otate 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 Heplacement 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 cl
32. e pistolet ou la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque rester distance e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche
33. ed 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 FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories 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 OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags
34. emblies 4 6 Months Batteries 5 90 Days Parts Guns TIG Torches Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry 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 replac
35. ement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers option of repair or replacement will be 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 inci
36. ents can give off toxic fumes if welded OM 193 472 Page 1 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 e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection T WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e 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
37. es une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et 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 soi gneusement avec des protections homologu es e Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables e Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le 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 e Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main 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 pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le cable 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 provoquant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des
38. hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller Effective January 1 2006 Equipment with serial number preface of LG newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retai
39. ire 1 E E 1907421 TUBE guide 0303035 22 DURS 182422 TUBE 045 062 2 P Eta beber 71 cree ee eee 010291 WASHER flat 625 x 1 250 OD x 125thk nylafil 1 44 093 551 KNOB pointer 3 A eee 2100 597 s PLATE CODUOlL asia dk teehee dei oh RE ink ed we ined bth 1 ET 187 909 HANDEE 2 Irun deals ee E 604 423 GRIP handle 1 Metus 188 674 LABEL caution incorrect lifting 1 192 526 CABLE power consisting of 1 079 739 CONNECTOR circ coc clamp 1 DR ee 600 797 CABLE port No 16 8 c 10ft 4in ft Prato 191 204 HOUSING PLUG 6 ue PLG7 115 093 HOUSING PLUG amp SKTS 7 PEGO sas 141162 42 5 HOUSING PEUG amp PINS id A d RR ER oes 1 PR etn ui at 010325 BUSHING strain 1 usare Ac edt ane
40. l purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years 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 nduction 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 Ass
41. lation 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 Toreduce 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 this welding machine is installed and grounded according to this manual e lfinterference 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 Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm For Gasoline Engines For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and
42. ls 1 Preflow Control Control sets time gas flows before welding wire is energized Time range is 0 to 5 seconds 2 Postflow Control Control sets time gas flows after completion of burnback Time range is O to 5 seconds 3 Spot Time Control Factory set for 0 25 to 5 seconds of spot time Rotating knob fully counterclockwise selects untimed continuous weld 4 Run In Control Use control to set wire feed speed before arc initiation Close side door Ref 802 357 A Ref 186 589 210 436 A SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance Disconnect power before maintaining Repair Or Clean And 4 Replace Tighten Labels Cracked Weld Weld Cable y Terminals y TO Replace Cracked Parts 14 Pin Cord Gun Cable Gas Hose Amd 6 Months Blow Out Or Vacuum D Inside Rolls During Heavy Service Clean Monthly OM 193 472 Page 17 5 2 Overload Protection Turn Off wire feeder and welding power source Stop welding engine generator 1 Circuit Breaker CB1 CB1 protects wire feeder from over load on Correct problem and manually reset breaker 802 349 A Trouble Remedy Wire does not feed unit completely inop erative Turn Power switch On Check 14 pin plug PLG2 connections Check input power Wire does not feed Check circuit breaker CB1 see Section 5
43. mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation OM 193 472 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit 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 Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 si
44. n knob Gun Trigger Plug Gun Trigger Receptacle Weld Cable Terminal Weld Cable From Welding Power Source Tools Needed J 9 16 5 8 in Ref 802 356 OM 193 472 Page 11 3 8 Optional Meter Circuit Board Settings 1 Meter Circuit Board 2 Switch S2 Set DIP switch S2 for type of welding power source and desired wire feed speed display see illustration Reinstall wrapper y S 1 2 NL X switch position does affect specified function Means switch must be in this position Voltage Sensing Function Arc Voltage Sensing Using Voltage Sensing Lead For Welding Power Source That Does Meters Minute Not Support Pins F And H NA AAA Digital Meter Display Or Inches Minute Arc Voltage Sensing Using Feedback From Welding Power Source That Does Support Pins F And H Tools Needed CO 1Ain Ref 802 357 Ref 186 266 OM 193 472 Page 12 3 9 Motor Start Burnback Control To change wire feed starting speed proceed as follows Turn Off unit and welding power source Remove wrapper 1 Motor Board PC1 2 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment Adjust potentiometer R73 using a small nonconductive screwdriver Rotate potentiometer clockwise to increase time it takes the motor to ram
45. nd e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e f 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 Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making inpu
46. nts example V Knurled roll in combination with U Grooved Drive Roll inlet PartNo Wire Guide 079 597 053 698 056 193 V S 0157 C OM 193 472 Page 25 Table 7 2 Drive Roll amp Wire Guide Kits 4 Drive Roll Base selection of drive rolls upon the following recommended usages V Grooved rolls for hard wire U Grooved rolls for soft and soft shelled cored wires U Cogged rolls for extremely soft shelled wires usually hard surfacing types V Knurled rolls for hard shelled cored wires Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Drive Roll Wire Guide Part No Type Inlet Intermediate 046780 053 695 056192 056 206 046781 053700 056 192 056206 191917 058 696 056 192 056 206 046 783 053 698 056 193 056207 V 1 16 in 046 784 053 699 056 195 056 209 1 16 in 046787 053706 056195 056 209 5 64 in 046 788 053 704 056 195 056 209 V 083320 083490 U Cogged 056193 056207 1 16 in 046 800 053 708 U Cogged 056 195 056 209 5 64 in 046 801 053 710 U Cogged 056 195 056 209 Ref S 0025 D 046 792 192958 056 192 056206 193 472 26 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
47. or 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 252 exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 gt USAGE 2 editae db Edere er La 1 Are Welding Hazardo e RIDERE REDE RARE uum deu a ee 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 06 3 5s Standards es curn deo Peer Depends jie e duo sarta Dan Da AU 4 156 IBITOFITIS BOTE su aac dida d i D
48. p up to speed 3 Burnback Potentiometer R42 Hemove protective white rubber cap before making adjustment Adjust potentiometer R42 using a small nonconductive screwdriver Rotate potentiometer clockwise to increase burnback time Reinstall wrapper ASSEMBLY NO 3 Tools Needed Non Conductive pO E FH CE 1 in Ref 802 357 192 653 OM 193 472 Page 13 3 10 Installing Wire Guide And Drive Roll Install and secure inlet wire guide on either assembly and intermediate wire guide on 4 drive roll assembly only Install drive rolls and turn drive roll nut one click During maintenance intervals remove drive rolls and clean grooves using a wire brush Check groove of drive roll for pitting or increase in the depth of the groove indicating drive roll is worn out Tools Needed 3 8 801 923 C OM 193 472 Page 14 3 11 Installing And Threading Welding Wire 1 Retaining Ring 2 Tension Adjustment Nut If necessary move hub on support for use of different size wire spool Remove retaining ring and install spool so hub pin fits spool hole Reinstall retaining ring Adjust tension nut so wire is taut when wire feed stops 3 Pressure Assembly Adjustment Knob Lay gun cable out straight A Open pressure assembly hold wire tightly and cut off end Push wire through guides into gun Close and tighten pressure assembly Press JOG button until wire comes o
49. roc dures suivantes OM 193 472 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 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 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les cables ensemble en les tordant ou en les enveloppant 2 Disposer les cables d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables 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 sou dure En ce qui concerne les s
50. s lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber LES FUM ES ET LES GAZ peuvent e Se servir d une source lectrique courant lectrique UNIQUEMENT si etre dangereux le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n Le soudage g n re des fum es et des gaz Leur cessaire se servir de la fonction de t l commande si l appareil en est inhalation peut tre dangereuse pour la sant quip e D autres consignes de s curit sont n cessaires dans les conditions Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s s
51. s 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 193 472 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd 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 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website 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
52. se e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed e 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 MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings design
53. t connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards 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 e 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 SIGNIFICANT DC VOLTAGE exists in in
54. te Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 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 souda ge causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin 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 lec triques 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 tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les p
55. timulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 INSTALLATION 3 1 Specifications T Wire f ype of Input Welding Power Wire Feed Diameter Welding Overall Weiaht Power Source Type Speed Range Range Circuit Rating Dimensions 9 Length 23 1 2 in 24 Volts AC Single Constant Voltage T i m 500 SES CSA Phase CV DC With 75 to 750 e 100 Width 10 3 4in 7 Amperes 50 60 14 And 9 To 19 mpm Max Spool Weight Duty Cycle 273 mm 990 Hz Contactor Control 60 Ib 27 kg Height 11 in 279 mm 3 2 Site Selection 1 Wire Feeder 2 Lifting Eye 3 Rubber Feet 4 Slot Choose slot that allows all rubber feet to sit securely on top of welding power source 5 Wire Spool Reel 6 Gas Cylinder Customer Supplied Shielding gas pressure not to exceed 100 PSI 689 kPa 7 Welding Power Source Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip 802 348 A Ref 152 468 155 242 801 919 B OM 193 472 Page 9 3 3 Gun Recommendation Table Process Gun GMAW Hard or Corded Wires M25 Or 40 FCAW Self Shielding Wires GA 40GL 3 4 Equipment Connection Diagrams CV
56. ur des structures m talliques telles que e Alint rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou e Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le ni
57. urit les dangers 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce manuel V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions l quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s de dans la Section 2 5 Lireet Ne pas enrouler les c bles autour du corps id pa Sila pi ce soud e doit tre mise la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre Pendantle fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l appareil Ne pas toucher des porte lectrodes connect s deux machines en
58. ut gun To adjust drive roll pressure press gun trigger to feed wire against wood surface Tighten knob so wire does not slip Cut off wire Close door 2 Tools Needed Q ceG 15 16in Ref 802 356 S 0627 A OM 193 472 Page 15 4 1 SECTION 4 OPERATION Front Panel Controls 4 G TRIGGER MADE IN LA VOLTAGE MILLER ELECTRIC MFG CO APPLETON WI USA v olo WIRE SPEED eje OM 193 472 Page 16 gr TRIGGER HOLD JOGYRURGE O 6 1 Optional Voltage Wire Speed Meter 2 Optional Voltage Wire Speed Switch Use to choose volts or wire feed speed display 3 Optional Remote Voltage Control Use to set welding power source voltage at the wire feeder Numbers are for reference only 4 Wire Speed Control 5 Jog Purge Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without ener gizing welding circuit or shielding gas valve Use Purge position to momentarily energize gas valve to purge air from gun or adjust gas regulator 6 Trigger Hold Switch Push up to weld without holding gun trigger throughout the weld cycle To start weld cycle press and re lease gun trigger within three se conds after an arc has been struck To end weld press and release gun trigger Power switch is on rear panel see Section 3 5 192 503 C 4 2 Optional Side Panel Contro
59. veau d oxygene provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute zl ment toxiques et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne vanis plaqu en plomb ou au cadmium moins que le rev tement n ait de terre du sectionneur ou que la fiche du cordon est raccord e une t enlev dans la zone de soudure que l endroit soit bien ventil et en prise correctement mise la terre portant un respirateur alimentation d air Les rev tements et tous les En effectuant les raccordements d entr e fixer d abord le conducteur m taux renfermant ces l ments peuvent d gager des fum es toxi de mise la terre appropri et contre v rifier les connexions ques en cas de soudage OM 193 472 Page 5
60. verter 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 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 lfinside 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 e 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 e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e 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 elem
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