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Mercedes-Benz 2011 GL-Class Automobile User Manual

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1. 1 AO ses de A 200 295 SWITCH rocker spdt 15A 12V on off on 2 dira cin 201 641 SWITCH rocker spdt 15A 12V on off on 2 a A nap 179851 KNOB pointer 1 670 dia x 250 id push on w spring 1 cada POL uiu 212459 CIRCUIT CARD ASSY trigger filter 2 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 222 394 Page 35 gt Hardware is common and not available unless listed See Table 10 1 For Drive Roll amp Wire Guide Kits 802 950 B Figure 10 3 Drive Assembly Wire Item Dia Par No Mkgs No Description Quantity Figure 10 3 Drive Assembly Wire Figure 10 1 Item 4 TA MI 010 668 SCREW cap stl sch 250 20 x 1 500 4 ERES Du pM M acta Se 172075 CARRIER drive roll w components 4 HUE PRENDE 149 962 SPACER carrier drive roll 4 DEC NM RR 149 486 PIN rotation arm rocker 2 T p 132 790 x FAN DIGSSUO a us lu sq er pia rd m ce b m ode 2 E E CMS 150 520 SPACER flat stl 257 ID
2. 2 sri G aaa unus cece le S alak 220 458 CABLE volt sense 23 iN dada scie dar cas o 15 eda S ER 213632 SWITCH rocker dpdt 10A 250VAC 20A 30VAC on none on 1 2193 ROT sce 211018 CONNECTOR circ 97 met 9 pin size 20 rcpt 1 as eee mia 221 989 FITTING w screen 1 O Rien tala atuk 137 761 NUT 750 npt 1 31 hex 27h nyl blk 2 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 222 394 Page 34 Item Dia Part No Mkgs No Description Quantity Figure 10 2 Control Box Figure 10 1 Item 21 Continued bate EN asawa kk tek 030 170 BUSHING snap in nyl 750 ID x 1 000 mtg hole 2 NE LO AAA 219047 VALVE 40 VDC 2 way custom port 1 8 orf w frict 2 n 125 473 HOSE SAE 187 ID X 410 OD X 27 000 1 Wo pu PE 097 132 STAND OFF SUPPORT pc card 8 RS gas W iu Sg aa B us 220 320 ENCLOSURE Control 221 d x Ee ed wh ea earn hee ae wok e toas 1 R SIDE ney Be ase 206 765 lt PANEL MORE uyayuq ii oe aaa 1 Mle EN 221081 NAMEPLATE lower
3. 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 stimulateurs 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 INTRODUCTION 3 1 Specifications Type of Input Welding Power Wire Diameter Welding Circuit Overall Power Source Type Wire Feed Speed Range Range Rating Dimensions Weight 40 Volts DC Axcess Series Standard 40 To 1400 ipm 1 0 030 To 1 8 in 100 Volts Length 27 in 686 87 Ib 10 Amperes To 35 6 mpm 0 8 To 3 2 mm 750 Amperes mm 39 5 kg 1007 Duty Width 12 1 2 in Max Spool Cycle 318 mm Weight 60 Ib 27 kg Height 14 1 2 in 368 mm 4 1 Selecting A Location Do not move or operate unit where it could tip Tipping Location Do not stack units Beware of tipping Lifting Forks Use lifting forks to move unit Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Sectio
4. OM 222 394F 2006 08 E Processes I er MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Description cv ES Wire Feeder Axcess Dual Wire Feeder OWNER S MANUAL Visit our website at File Advanced Manufacturing Systems W 4 www MillerWelds com ams We From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir Y E BI E Her 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 Con ete jue ere ex e i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable serv
5. veWriter software the Program Display will have a C in front of the program number This indicates that the program is not a factory default program and has been modified By selecting or changing any process variable and performing a program load will restore the program back to the factory default program Pressing and holding the Process Set Up push button in on power up allows viewing the software revisions of each circuit board in the system The top display shows the board PCM UIM WFCM and AIM auto mated units only and the lower display shows the last 3 digits of the circuit board part number plus a letter designator Press the flashing Feeder Set Up push button to exit the screen displays and continue the power up process Table 6 1 Welding Wire And Gas Abbreviations Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation Steel STL E70 E100 E120 100 CO CO2 90 Argon 10 CO C10 85 Argon 15 COs C15 75 Argon 25 CO C25 95 Argon 5 CO C5 95 Argon 5 O OX5 98 Argon 2 O gt OX2 Stainless Steel SS 308 309 312 316 98 Argon 2 Oo OX2 81Ar 18HE 1C0O gt Tri Gas Accu pulse 90HE 7 1 2Ar 2 1 200 gt Tri Gas MIG RMD Cored Tubular Wire MCOR 71 76 86R 409 90 Argon 10 COs C10 98 Argon 2 O gt OX2 Aluminum ALUM 4XXX 5XXX 100 Argon ARGN Not all wire types may be available with your unit OM 222 394 Page 23 6 11
6. parts 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 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 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 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 lf 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 Welding or cutting equ
7. rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact e 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 la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ces 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 II 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 e Ne pas se servir de source lectrique a courant lectrique dans les zo nes Lo sg dans les enarelts comings ed l o on risque de tomber LES FUMEES ET LES GAZ peuvent e Se servir q une source lectrique a courant lectrique UNIQUEMENT si tre dangereux le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n Le s
8. yel cud tous 167 387 i SPACER 1OCAlINg 52 Ra a toes cente or Ett ao AAA 2 OM 222 394 Page 36 Item Dia Part No Mkgs No Description Quantity Figure 10 3 Drive Assembly Wire Figure 10 1 Item 4 continued e yapa gia dd 108029 i4 DRIVE DINION 3 ve s aia dais 1 R ND us seu 133 308 RING retaining ext 375 shaft x 025thk 1 UP 134 834 HOSE SAE 187 ID x 410 OD order by ft 2ft UN M ee 184 685 ADAPTER ASSY gun feeder LH including uu AU ELA 149 959 FITTING brs barbed M 3 16tbg x 312 24 1 E er dot de 179265 ADAPTER gun feeder 1 VD puse M E TE 604 538 WASHER flat stl SAE 312 1 Eo ERE 151437 KNOB plstc T 1 125 lg x 312 18x 1 500 1 po E ta ua 185624 SCREW 010 32 x o 50 hexwhd 40D stl pld slffmg trilob 2 ac A 601 872 NUT stl hex full fash 375 16 1 palo aza are tens waya a 602 213 WASHER lock stl split 375 1 LO Z Aan iwa a ti bos 602 243 WASHER flat stl std 375 1 EU 601 966 SCREW cap stl hexhd 375 16 x 1 250 1 NC EE PE qhasa 108 940 SCREW cap stl hexhd 250 20 x 750 4 PLC
9. Dot a a bd ed DAC Ee V d is 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS USES e ana pusa uuu uama re etse dnce o ee Dalee aad eh y Sas kis d k aN 5 2 2 Dangers relatifs au soudage l arc 2 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 s scm oae doe eua ede mes Act Re tnt oD as 8 2 6 Information EMP vs s eux sum doe ele ER a wena OR a RU e NE ero ge ue de 8 SECTION 3 INTRODUCTION Z desde ees S s oth Cowden wes a EE IE EROR E FACER ROS oe umasa UR e Sk 9 ds lu Opeci icalons orar a P EP 9 SECTION 4 INSTALLATION cc ti aa 9 As 5elecuhgA Location ess is LA Lae d md tcs geek Gen eure Ry A 9 4 2 Connection Dagia vezes cecus Qeteta bat Sie ee tales quet onis SA AS ASADO Oa ae 10 4 3 Rear Panel Connections And Rotating Drive Assembly 11 4 4 9 Pin Network Receptacle Information mnn 12 4 5 Gun Recommendation Table 0 0 ccc ene hh hr rn 12 4 6 Installing And Threading Welding Wire 13 4 7 Power Source Display At Power Up rrr ren 14 4 8 Dual Schedule Switch Opti
10. PLG83 lt RO31 2 lt RCB1 6 RC80 4 gt B lt RCH1 5 R SO 7 gt R80 87 en TACHOMETER PICK UP PC51 PCS RCBO 1 39 GUN ADAPTER lt RCB1 amp 20 X RGBI 1 FILTER lt RC83 2 ncag pi a0 RGB1 PLG81 RCB2 PLGA2 RCB2 PLGBJ TACHOMETER PICK UP FCa1 LEFT MOTOR MOTOR HOUSING ales m MOTOR HOUSING an h 218 564 D OM 222 394 Page 31 SECTION 10 PARTS LIST gt Hardware is common and not available unless listed 4 Figure 10 3 21 Figure 10 2 804 023 A Figure 10 1 Main Assembly OM 222 394 Page 32 Item Part No No Description Quantity Figure 10 1 Main Assembly M de na 159 647 INSULATOR motor clamp 2 FE PI 159646 CLAMP motor base 2 TEMPE 159 360 INSULATOR screw machine 8 pad uua ee ee Figure 10 3 DRIVE ASSEMBLY wire S L4roll 1 E aysa a Te 143 160 HUB amp SPINDLE ASSEMBLY including 2 E ETE n 058427 RING retaining spool 1 cr 180 573 SHAFT ASSY support spool 1 DL DH THE 010233 SPRING cprsn 970 OD x 120 wire x 1 250pld 1 Tm A tus iera usa 057971 WASHER flat 632 ID x 1 500 OD x 125thk stl pld 175 keyed 2 E 0 aia
11. Pulse Accu pulse or RMD optional To exit Arc Ctl or INDU either press the upper display push button or press and hold the lower display push button for 2 seconds 7 When the lower display push button LED and the WFS LED are both illuminated it is possible to change WFS while welding by using the Adjust knob The value in the display will switch momentarily to show preset wire feed speed while turning the Adjust knob and revert back to actual value when adjustment is completed When the Arc Ctl LED is illuminated it is pos sible to change values while welding by using the Adjust knob To return to actual values on the display exit the Arc Ctl display The lower display push button has addi tional functions when entering the se quence and trigger control functions see Section 6 8 OM 222 394 Page 21 6 8 Feeder Set Up Push Button Sequence Start Crater Trigger Control Time Time Trigger Hold L Preflow CA x i Sequence Diagram Feeder Set Up 1 Feeder Set Up Push Button LED 2 Feeder Set Up Push Button e Press button to choose Sequence Feeder the Upper Display push button e The Sequence option STRT and CRTR will have additional parameter settings By ger control selections Use the Adjust knob to cycle through the trigger control methods as follows DS TH TDS TPS and 4T see Section 5 1 for definitions The lower dis Set Up push button LED will illuminate 3 Sequence LED
12. a selection turn the Adjust knob Pressing the Process Set Up push button a third time will keep Wire Type LED lit and the upper display will show wire alloy type see Table 6 1 for alloy types The upper display push button LED will be flashing indicating that turning the Adjust knob will change the alloy type for the selected process and wire type e Pressing the Process Set Up push button a fourth time will keep Wire Type LED lit and the upper display will show wire size The upper display push button will be flashing indicating that turning the Adjust knob will select wire sizes available for that particular process and wire type Pressing the Process Set Up push button a fifth time will illuminate the Gas Type LED and the lower display will show GAS and the upper display will show gas selection see Table 6 1 for gas abbreviations To make a gas type selection turn the Adjust knob If any of the Process wire type alloy type wire size or gas type was changed then pressing the Process Set Up push button a sixth time will show PROG in the upper display and LOAD in the lower display The new program would be loaded for that particular program in slot 1 thru 8 If no changes were made to any setup items no program will be loaded and unit will return to standby mode 1 Process Set Up Push Button 2 Process Set Up LED 3 Program Selection LEDs If a custom program is loaded using an optional PDA with File Management Wa
13. gt Hardware is common and not available unless listed 804 024 C Figure 10 2 Control Box Item Dia Part No Mkgs No Description Quantity Figure 10 2 Control Box Figure 10 1 Item 21 ee DE 220 321 WRAPPER feeder dual Axcess 1 2 casis den b ape b a kus 134 464 LABEL Warning General Precautionary 1 o RE 211 164 PANEL pc card switch overlay including 1 de deteste 210655 NAMEPLATE overlay 1 TR IPOD wins 227 879 CIRCUIT CARD ASSY switches 1 0D usse IPOT GO 204049 USER INTERFACE MODULE 1 Par s POG ai 209681 WIRE FEED MODULE l yv E ER mE Rex s 1 MEO DUET NEM 134201 STAND OFF SUPPORT pc card 16 EE 0 REPE 212493 CIRCUIT CARD ASSY motor filter 2 dL uci c 220 063 CIRCUIT CARD ASSY relay 1 Manu p A 010494 BUSHING snap in nyl 1 375 id x 1 750 mtg hole 2 DER nasa as 220 314 FILTER ASSY sense lead including 2 NO A RS 038 855 BLOCK term 20 amp 2 pole screw term 2 le un ee se 216696 CAPACITOR w terminals O27UF 2 PR LP E 224383 RESISTOR w terminals 2K 5 watt
14. high F 24 volts dc common G 24 volts dc H Motor voltage 40 volts dc common Motor voltage 40 volts dc 4 5 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires 400 500 And 600 Amp Air Cooled Guns GMAW Pulse Water Cooled Guns OM 222 394 Page 12 4 6 Installing And Threading Welding Wire Install wire spool Adjust tension nut so Install wire guides and wire is taut when wire feed stops anti wear guide Install drive rolls TITI NI Pressure Indicator fo ini aM P el ND LN Tools Needed db 3 16 5 64 in Et S 15 16 3 8 in Drive Rolls 2 Cable End Of Liner gt Be sure that outlet cable has proper size For soft wire or small diameter stainless gt To adjust drive roll pressure hold nozzle liner for the welding wire size When steel wire reduce drive roll pressure on about 2 in B1 mm from nonconductive installing gun position liner the rear roll to half that of the front rolls surface and press gun trigger to feed wire extending from outlet wire guide as against surface Tighten knob so wire close as possible to drive rolls without does not slip Do not overtighten If con touching tact tip is completely blocked wire should slip at the feeder see pressure adjust Install gun Lay gun cable out straight Cut off ment above Cut wire off Close cover end of wire Pus
15. the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton 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 a
16. un risque la sant humaine gt Toutefois des tudes sont toujours en cours et les preuves continuent a 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 proc dures suivantes OM 222 394 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou Toronto 416 747 4044 site www csa international org t l phone 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
17. 8 1 SECTION 8 MAINTENANCE Routine Maintenance Disconnect power before maintaining gt Maintain more often during severe conditions Y Check Change Clean To be done by Factory Authorized Service Agent Replace Reference Afi SM x Unreadable Labels Weld Terminals x Damaged Gas Hose X Weld Cables Months Gil Mix Cords X Gun Cables X Cracked Parts Every 6 Months Drive Rolls Inside Unit OM 222 394 Page 26 8 2 Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors Explanations are in the text below TACH MOTR WFS STRT Indicates a motor error Indicates a tachometer error Indicates an arc start error Indicates a wire feed speed error Indicates a coolant flow error Indicates a ground current error ERR TACH e The tach error occurs 2 seconds after the loss of tachometer feedback The motor speed is regulated through the monitoring of voltage and current Press Jog Purge button to clear error ERR MOTR e The motor error indicates that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torque load duty cycle Press Jog Purge button to clear error ERR WFS e The wire feed speed error indicates actual wire feed speed does not match wire feed speed c
18. Arc Gouging process selection 6 7 Lower Display e Time ues Is ki WFS Qe o E Ctl 1 Lower Display The lower display shows WFS wire feed speed AMPS amperage ARC CTL arc control or Time The feeder displays only preset wire speed at idle not welding While welding the average amperage is displayed The lower display shows welding sequence time when the Time LED is illuminated 2 WFS Wire Feed Speed LED LED illuminates to indicate the preset wire feed value is being displayed and can be adjusted using the Adjust knob 3 Amps LED LED illuminates to indicate the average amperage is being displayed while welding and for 3 seconds after welding is terminated The amperage must be above a minimum value of 25 amps for this function to operate 4 Arc Ctl Arc Control LED LED illuminates to indicate that inductance MIG or ARC Pulse Accu pulse or RMD optional is being displayed and can be ad justed using the Adjust knob 5 Time LED LED illuminates to indicate that a time value is being displayed for a sequence function and can be adjusted using the Adjust knob 6 Lower Display Push Button 7 Lower Display Push Button LED Pressing the button illuminates the LED and selects either WFS or Arc Ctl value for changing using the Adjust knob To select Arc Ctl press and hold lower display button for 2 seconds The top display will show either INDU for a MIG program or ARC for
19. M 179 263 COVER drive roll consisting of 1 aku a G dosis ui idol dia 178937 LABEL warning electric shock Recommended Spare Parts 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 Table 10 1 Drive Roll And Wire Guide Kits Inter V GROOVE U GROOVE VK GROOVE UC GROOVE mediate Drive Drive Drive Drive Guide Roll Roll Roll 150993 149518 151026 053700 151036 072000 151052 132958 150993 149518 161189 053 696 pan NE MEM NN i ee in 150 995 149 520 151029 053699 151039 053706 151055 132955 151 072 053 708 um inj 150 995 149 520 4 4 151 040 053 704 151057 132960 151073 053 710 m in 150 996 149 521 151 041 053703 151058 132961 151074 053 709 do ss 150 996 149 521 pl 151042 053705 151059 132962 151 075 053 711 As 159 997 149 522 151043 053707 151 060 132963 151076 053 712 Each Kit Contains An Inlet Guide Intermediate Guide And 045 233 Antiwear Guide With 604 612 Setscrew 8 32 x 125 Along With 4 Drive Rolls Roll ES NM EN ET legal i OM 222 394 Page 37 Notes Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get
20. 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 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 SECURITE 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 LN W z Ce groupe de symboles signifie Avertissement Attention Risq
21. RC 27 3 3 TTOBDIGShoOHITO r does u od eh Eat eee de late bed oo vedo sg dete Qasa sos w eur ndr Qa ees 29 SECTION 9 ELECTRICAL DIAGRAM 3 ru xir expe mets a wee 30 SECTION 10 PARTS LIST 30002 CR cares new eee came ei ne Cri a Sade 32 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 Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols gt Means Note not safety related 1 2 Arc Welding Hazards Thesymbols 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 c
22. Reset Mode Process Wire Type Gas Type Adjust Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed RST NO message will not display until after the power up sequence is completed approximately 20 seconds RST Program Volts Arc Length RST Volis Arc Length Arc Control YES II 9 WireSpeed Amps Process e Wireteed Wire Type Gas Process Wire Type Gas Type Contactor Gas Type TO E Sep Adjust Are Control fo Rotate Adjust knob to change NO to YES YES Hi 9 WireSpeed Amps Wireteed Gas Contactor Adjust Arc Cont EY Press the Arc Control button to confirm the reset The reset message is displayed for 2 seconds while factory program settings are being reloaded During the reset mode the following factory default programs are loaded into the unit Program 1 Program 2 Program 3 Program 4 Program 5 Program 6 Program 7 Program 8 OM 222 394 Page 24 Pulse 035 Mild Steel 90 Argon 10 CO MIG 035 Mild Steel 75 Argon 25 CO Accu pulse 035 Mild Steel 90 Argon 10 O2 Pulse 045 Mild Steel 90 Argon 10 CO MIG 045 Mild Steel 75 Argon 25 CO Accu pulse 045 Mild Steel 90 Argon 10 O2 Pulse 052 Mild Steel 90 Argon 10 CO MIG 052 Mild Steel 75 Argon 25 CO Reset mode is not acti
23. TOR CONTROL 41 1 34 asas IS 4 2 RC1 PLO1 RC1 2 lt J15 2 MICROPROCESSOR 11 mee RIGHT zu 3 J1 PLGAO Hsc RC4 4 RCI a Aa e 4 J2 FLG42 43 40NDC ji J5 PLO41 48 727 J6 PLGS1 T to i JB PLC52 J10 PLG43 37 J1 3 gt cos 6 J11 PLG49 J12 PLG44 di 3 PLG45 PURGE 59 J14 PLG46 LEFT FI NN dn j J16 PLG48 s3 lt J12 2 J14 5 Pagus MET dn m P6 4 J14 7 gt gt __4 EB 45 1 E 45 2 EINE 5 oi S2 RC1 2 gt 0 2 J17 1 gt RC1 PLG1 LEFT ros gt RGI 3 gt lt 18 OR A 7 y 2 8 417 32 RC4 4 9 RC1 a t J8 amp 4 5 T s 4 m d b l 4 dis z gt 41 rcs y V A EUR AM OMS IN 37 7077 17 m lt RCZ 4 lt RC2 7 PCS soe O X RC2 RC2 PLG2 TU to s po pns m RC1 1 S106 RCS J3 a E E 48 GENE DE 54 ZACH COMMON 55 ZACH A 56 ZACH E 57 GAS VALVE 58 GAS VALVE OM 222 394 Page 30 Figure 9 1 Circuit Diagram ELECTRODE SENSE 3 S1 O 67 LLEETRODE SENSE TACH COMMON 3 ZACH A 32 ACH IV 69 IACH amp et E 35 GS ES 388 E MOTOR 41 MOI 65 Ho rn RG1 6 gt RG3 2 RC1 4 Ro1 3 gt gt 70 68 RC1 RC3 1 TACH SV 70 MTOR RCeB3 1 ELECTRODE SENSE 6 PC7 DISPLAY MODULE 13 PLG72 RC1 A C1 z 14 RQ1 G RC1 F RC1 E RO1 D BARE RC1 B RC1 C 2 12 ROT RC1 H lt RCB1 1 FE FILTER RCSQ PLG80 X RC81 4 RCB1 PLGB1 ROB80 6 lt Rca1 7 RCS2 FLG82 peao s DER RC83
24. Trigger Hold LED will illuminate Trigger Hold is automatically set to On with the 4T trigger selection This is part of the 4T function return the system to standby mode 4 Trigger Control LED e Press the Feeder Set Up button twice and by turning the Adjust knob By entering a time value the sequence state will become active To turn off a sequence state change the time value to OFF To step back for selecting another sequence option press 6 9 Adjust Knob OM 222 394 Page 22 the Trigger Control LED will illuminate and the upper display will show the different trig e Press the Feeder Set Up button a third time to cycle back to standby mode 1 Adjust Knob The Adjust knob is used to change functions and parameters Refer to the front panel sections for information regarding use of this control 6 10 Process Set Up Push Button process Wire Type Gas e Process Set Up e Press the Process Set Up push button the first time will illuminate the button LED and the Process LED The upper and lower displays will be used for Accu pulse and only the lower display for MIG Pulse and RMD optional to show the current process installed in this program To change process turn the adjust knob Pressing the Process Set Up push button a second time will illuminate the Wire Type LED and the lower display will show wire types available for selected processes see Table 6 1 for wire abbreviation To make
25. age 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 tincelles 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 q
26. aim 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 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 GQ Miller
27. arranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an 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 ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls 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 Brande
28. cks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit IX FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas c
29. d Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry 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
30. d 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 site 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 a propos de tels champs Cependant apres 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 lt Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques a haute fr quence repr sente
31. e When the Feeder Set Up button is pressed once the Sequence LED will illuminate and the upper display will show sequence options Use the Adjust knob to select PRE preflow STRT start CRTR crater or POST postflow Press the lower display push button and the Lower Display push button LED will illuminate as well as the lower display The Time LED will automatically begin flashing indicating that a time value can be entered pushing the Lower Display push button a second time while STRT or CRTR appear in the upper display allows entering voltage MIG or Arc Adjust Pulse Accu pulse or RMD optional Use the Adjust knob to change the values indicated by the flashing LED for either Volts or Arc Adjust Pressing the Lower Display push button a third time will activate the WFS setting for either STRT or CRTR and the WFS LED will begin flash ing Use the Adjust knob to change the WFS value Pressing the Feeder Set Up button two more times will exit the Sequence menu and play will show the current state of each trig ger control method as being on or off Not all trigger control methods are compatible with each other therefore turning on certain trig ger selections will cause other trigger selec tions to turn off Press the lower display push button to illu minate the push button LED and enable the use of the Adjust knob to allow turning se lected trigger control methods on or off If trigger hold is set to on the
32. e 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 e Tenir les 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 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 f
33. e 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 PIECES 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 le 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 e 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 un
34. elected program information into program slot Preset voltage in MIG mode at idle actual voltage while welding and 3 seconds hold value at end of weld Indicates time values being set for timed functions e g Preflow Postflow which are only available in the Arc On and Analog input or the Arc On and No Analog input modes Distance from end of wire electrode to workpiece Term used to represent wire feed speed In MIG mode wire feed setting is independent of voltage setting In pulse Accu pulse and RMD optional adjusting wire feed speed also increases power level on wire electrode one knob control Indicates average amperage while welding and 3 seconds hold value at end of weld Allows setting of inductance in MIG mode In pulse and Accu pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory pulse data In RMD optional this control will affect the in much the same way as inductance In short circuit GMAW welding an increase in inductance will decrease the number of short circuit transfers per second provided no other changes are made and increase the arc on time The increased arc on time makes the welding puddle more fluid Control knob used to change or set parameters and functions OM 222 394 Page 15 General Terms Sequence Preflow Start Crater Postflow Feeder Set Up Auto Thread OM 222 394 Page 16 Selecting Sequence will allow setting of preflow start crater and po
35. er 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 gachette 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 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 qu 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 panneau
36. error indicates welding power source primary current is too high Check and correct input power Press Jog Purge button to clear error LOW WFS e The low wire feed speed error indicates actual wire feed speed is lower than wire feed speed command Check for obstructions in the wire feed system or a faulty wire drive system Press Jog Purge button to clear error E STOP e The emergency stop error occurs if the user presses an emergency stop button Reset the emergency stop button and press Jog Purge button to clear error RMD DONE e The RMD done error indicates the RMD demo is completed Press Jog Purge button to clear error OM 222 394 Page 28 Indicates a low WFS command error Low E wrs Indicates an emergency stop error OVER AVER e The over average error indicates that cur rent is outside the average range for the set program parameters Check and correct program parameters Press Jog Purge but ton to clear error REL TRIG e The release trigger error indicates the user held the trigger when starting a weld program Press Jog Purge button to clear error ERR UNKN e The unknown error indicates a malfunc tion in the system somewhere Press Jog Purge button to clear error 8 3 Troubleshooting Disconnect power before troubleshooting Trouble Remedy Wire feeds shielding gas flows but electrode wire is not energized Check and secure weld cable connections see Sectio
37. ewise decreasing arc adjust shortens arc length Arc Adjust is replaced by volts in MIG programs Selecting Trigger Control allows activating trigger functions such as DS TH 4T TDS and TPS Dual Schedule allows selecting a pair of programs that can be used together Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger In trigger hold mode momentarily press gun trigger and wire will feed until gun trigger is momentarily pressed again 4T allows the operator to select between weld parameters and crater parameters using the gun trigger Crater time must be set for at least 0 2 seconds to make this function operational If gun trigger is released during welding unit goes into trigger hold then pressing and holding trigger again causes unit to stay in crater until trigger is released and crater parameter times out TDS allows the operator to select between a pair of weld programs by using the gun trigger In TDS mode momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected weld programs TPS allows the operator to select weld programs by using the gun trigger In TPS mode momentarily pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total of 8 programs Eight active slots for selection of various processes wire type and parameters A selection made for MIG Pulse Accu pulse and RMD optional CV weld process wit
38. h individual settings of voltage and wire speed Conventional pulse program using peak background pulse width frequency and peak voltage as factory taught data Adaptive method is controlled by frequency adjustment Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds Adaptive response is controlled by peak and minimum current levels Benefits are shorter arc lengths better puddle control more tolerant of tip to work variation less audible noise no arc wandering allows weld to fill in at toes increasing travel speed and deposition and more tolerant to poor fit up and gaps CV Pulse process designed for high travel speeds Typically used in Robotic applications Arc is de signed to be tight and fast Front panel display is ACCU SPED CV Pulse process using a pulse waveform with modified curves at particular locations within the wa veform Has a distinguished change in arc characteristics Front panel display is ACCU CURV RMD refers to Regulated Metal Deposition A precisely controlled short circuit transfer Benefits of RMD are well suited to thin materials improves gap filling and spatter reduction Provides less heat input into workpiece minimizes distortion and allows use of larger diameter wire on thin gauge materials Selection of wire type by alloys and classification Selection of shielding gas being used in application Selection procedure for entering program Enters s
39. h wire through guides up to drive rolls continue to hold wire Once wire has reached the liner auto thread wire by momentarily pressing Purge and quickly pressing Jog to begin auto threading wire Ref 156 929 A Ref 150 922 Ref 156 930 802 954 S 0627 A OM 222 394 Page 13 4 7 Power Source Display At Power Up Lu Program NEN Volts 6 Time 6 Arc Length 1 Upper Display 2 Lower Display e NEN O Amps O Arc Ctl 2 Process Sequence Wire Type Trigger Control Gas Type Trigger Hold e Process Set Up j Feeder Set Up Power Source Upper Display Lower Display Voltage Range e w _ P Pc or 4 8 Dual Schedule Switch Option 1 Maint 2P Maintained Contact 2 Pole Switch DSS 9M Part 041 793 1 DSS 9M 1 OM 222 394 Page 14 SECTION 5 OPERATION 5 1 Operational Terms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder General Terms Arc Adjust Trigger Control DS Dual Schedule TH Trigger Hold 4T TDS Trigger Dual Schedule TPS Trigger Program Schedule Program Process MIG Pulse Accu pulse Accuspeed AccuCurve RMD optional Wire Type Gas Type Process Set Up Program Load Volts Time Arc Length WFS Amps Arc Control Inductance Adjust Term used to represent arc length adjustments in pulse programs Increasing Arc Adjust increases the actual arc length Lik
40. ice with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in SU ba os 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 ur Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad OY MPSS AO O ae ae Rae ae ee hae tad li ie sd Mn ade eae 1 162 Are Welding Hazard y tar o oe et kaa Ae de a oa alee deu aie ee A qua 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings mrs 3 5s Principal sale Standard es curn deo Peer Depends jie fast e duo sarta Dan So maa Da AU 4 156 EME IBITOFITIS BOTE rita d i Dar ti a Sinker n c acr d o
41. ing 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 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 d
42. ipment 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 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 222 394 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 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 Com
43. ircuits 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 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 po
44. leet aes p se 010191 WASHER flat 656 ID x 1 500 OD x 125thk fbr 2 ble ar Sa ne 058628 WASHER brake stl 2 E CREDERE 058 428 1x HUB SDOOl ya d a a PC ER eco i ede eg he ede de 1 TE oe eee ae 071 730 TUBING stl 875 OD x 12 ga wall x 2 500 1 uL 135 205 NUT 625 11 94 hex 77H stl pld elastic stop nut 1 blac m AAA 2 SUPPORT SPOOL LAS she eite ox iia praia ict 1 TG HS 208 339 KNOB w extension LH clamp 1 MO o ee est 208 338 KNOB w extension RH clamp 1 ds am maura um s 156243 CLAMP motor toD 2 lo ue rite 145 639 STRIP buna N compressed sheet 062 x 4 000 x 4 000 2 ls mie sine 139220 es BASE A ele et ed een de 1 BOLO arc ers LU UE 134 306 FOOT rubber 1 250 dia x 1 375 high no 10 screw 4 AE dans Figure TO 2 CONTROLBOX Livni rimar d nep gl Da 1 O ira laa 220 350 DRIVE ASSY wire RT 4 roll 1 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 222 394 Page 33
45. llow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 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 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 cl
46. n 20 4 Extend forks beyond opposite side of unit 2 Hand Cart Use cart or similar device to move unit 3 Rating Label Use rating label to determine input power needs 4 Line Disconnect Device INPUT SERIAL NO lt STOCK NO VOLTS AMPERES KW PHASE Locate unit near correct input power supply loc_2 3 96 804 018 A OM 222 394 Page 9 4 2 Connection Diagram Welding Power Source Wire Feeder Gas Cylinder Gas Hose Network Feeder Cable Negative Weld Cable Workpiece 8 Voltage Sensing Lead Recommended for Accu pulse and RMD optional gt Positive voltage sensing lead is contained in the motor cable 9 Positive Weld Cable 804 019 A OM 222 394 Page 10 1 9 Pin Network Receptacle 2 Power Switch 3 Shielding Gas Valve Fitting Left And Right Requires fitting with 5 8 18 right hand threads Connect customer supplied gas hose 4 Weld Cable Terminal 5 Jumper Cable 6 Weld Cable 7 Drive Assembly 8 Drive Assembly Rotation Knob Left And Right 9 Rating Label Location To rotate the drive assembly loosen drive assembly rotation knob rotate drive assembly and tighten knob gt a 2 2 WS Tools Needed YT 9 16 5 8 in 804 020 A 802 825 A OM 222 394 Page 11 4 4 9 Pin Network Receptacle Information 7 END LE G Pin Pin Information A Capacitor C1 to ground B Shield C Volt sense D Can low E Can
47. n 4 2 Electrode wire feeding stops or feeds erratically during welding Check gun trigger connection See gun Owner s Manual Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 4 6 Change to correct size drive roll see 4 6 Clean or replace dirty or worn drive roll Incorrect size or worn wire guides Replace contact tip or liner See gun Owner s Manual Remove weld spatter or foreign matter from around nozzle opening Have Factory Authorized Service Agency check drive motor or motor control board PC1 Motor runs slowly Check for correct input voltage Wire feeder power is on displays light up but unit is inoperative Check welding gun trigger leads for continuity and repair leads or replace gun OM 222 394 Page 29 SECTION 9 ELECTRICAL DIAGRAM WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD CAN H EAN L 24 COMMON 19 RIGHT BA AA AA uo Z4 PURGE lt 13 12 VM 410 2 a L nb ue d I Z COMMON Eu ES N J10 5 gt sz Ma x x 3 3 5 CAN H 410 17 i lt J13 11 CAN 1 4 410 47 Ey PC6 J10 3 gt 4 RC4 1 gt P RC1 1 gt lt 115 1 MO
48. ns Ne pes souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 222 394 Page 5 LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et a 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 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 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 soud
49. o 700 ipm until the Jog switch is released e The unit also provides the ability to jog the wire feeder by means of the gun trigger When the gun trigger is pressed without starting an arc the wire will feed at run in speed for the first 3 seconds During this time OCV open circuit voltage will be pres OM 222 394 Page 18 ent as indicated on feeder upper display Af ter 3 seconds the weld output turns off and the wire will feed at 60 ipm for the next 3 sec onds and then ramps up to 700 ipm until trig ger is released or 30 seconds elapses If the gun trigger is still activated after 30 seconds the jog operation is terminated to prevent complete unspooling of the wire and an ERR STRT message is displayed on the upper and lower displays Releasing and pressing the trigger again will clear the error gt If Start Error is enabled using an optional PDA with File Management WaveWriter software an ERR STRT will occur after 1 Jog Purge Push Button 2 Gun Trigger Receptacle 3 Adjust Knob 804 022 A the first 3 seconds of run in and jogging from the trigger is not possible e Pressing right side of the Jog Purge switch allows the operator to purge gas lines before welding and to preset gas pressure at the regulator This unit is equipped with Auto Thread capability By rocking the switch from purge to jog within 0 5 seconds will automatically feed wire for a factory default setting of 192 in 4877 mm of
50. oing 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 222 394 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use 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 e 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 sho
51. ommand Press Jog Purge button to clear error ERR STRT e The start error occurs if the user has the trigger held for more than 3 seconds without striking an arc or if a valid arc voltage and current is not detected The 3 second arc start error time can be changed using an op tional PDA with File Management software Indicates a temperature error Indicates a wire stuck error ERR STOP e The stop error occurs as result of obstructions in the wire feed system or a faulty wire drive system Check wire feed and wire drive systems Press Jog Purge button to clear error ERR FLOW e The flow error indicates no gas flow to the gun The error may be reset by reestablishing gas flow to the gun and then pressing the Jog Purge button ERR COOL e The cool error indicates no coolant flow in water flow switch option The error may be reset by reestablishing coolant flow to the gun and then pressing the Jog Purge button ERR GND e The ground current error occurs if weld current is detected in the earth ground connection May be caused by a conductor making contact with unit chassis Check and repair feeder weld connections Press Jog Purge button to clear error Indicates an arc stop error FLOW Indicates a gas flow error ARC Indicates an arc error LINE Indicates a line error ERR STUK e The stuck error occurs if the welding wire sticks to the workpiece at the end of a weld May be caused by po
52. on n 14 SECTION 5 OPERATION ina st A WOO e RO as RO OR US Vies 15 0 ls Operational Tennessee od doch ci d c m lc bande a RR Pe Rad dod T m RD iia E 15 SECTION 6 OPERATION sise es merae low ede ex e kas ees MEAS SER eee E A E YE 17 Galih FOWE SMIICNE PPP 17 6 2 Let Right Select SMIC ee ere nae heady eee Mae ee DR CUN BOLA OS ew e eee ees 17 6 9 JOQ PUITO x bus d nes oce saos Nisqa hiss d eg e ec ace eat Boves ia mele bs eee e 18 6 4 Front Panel S9cllols x xeu dew tee e Race o ic cae De dc ate UE ace VE ne Ion 19 6 5 Program Push BUON s uuu asses o ob e ROS ac ec axe ers aod a ee de le dc eue ee 20 6 6 Upper Display vs sat wad Robes ec ce tee acto qe Baba ca ce Rio d ctt ela LR yas k hay t Coburn 20 pr LOWER DISIA Y EEE eas oe eee tetrad NN A eng Sidus Stn qu eR rc 21 6 8 F ed rSet Up Push BUUON anotar te RE d ex RUE RE OX Cx Pa d en tae M Ye Pts 22 6 9 gt SAJIUSUNDOD seca Geek tee ice emi ne HE Een tc dena dun taba ido band eeu Slt ee s ates d 22 6 10 Process oeEUD PuslcBUHOIasss aso AAA EYE MESS 23 O ROSE gie RE EM 24 SECTION 7 SETTING SEQUENCE PARAMETERS nnn 25 7 1 Sequence Parameters In A Program a 1 25 SECTION 8 MAINTENANCE sn A eae D e E ma Q Qo er cede eru ce eee 26 8 1 Routine Maintenance mex Lot DERE Oe ROS Ae ae EON RC Ro Cx d ee oce o wc i dota d e anus 26 921 PIAQNOSIICS
53. onctionnement 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 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 cote oppose 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 approch
54. 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 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 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 e 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
55. or weld conditions The error may be cleared by cutting wire from workpiece and pressing the Jog Purge button ERR TEMP e The temperature error indicates welding power source has overheated and shutdown The error may be cleared by allowing unit to cool down and pressing the Jog Purge button ERR LINE e The line error indicates input power is outside of unit operating range Check and correct input power Press Jog Purge button to clear error ERR ARC e The arc error indicates an arc outage occurred possibly from a wire feeder error or power source error Check wire feeder and power source Press Jog Purge button to clear error OM 222 394 Page 27 8 2 Diagnostics Continued Indicates a weld cycle wait error Indicates an overcurrent error Indicates a UIM communication error Indicates a motor communication error AVER TRIG UNKN Indicates an over average current error Indicates an arc error Indicates an unknown error Indicates a trigger closed error WELD WAIT e The weld wait error indicates unit was not ready for a weld sequence Press Jog Purge button to clear error MOTR COM e The motor communication error indi cates motor board lost data communica tions Press Jog Purge button to clear error PLS WAIT e The uim communication error indicates user interface board lost data communications Press Jog Purge button to clear error OVER CRNT e The over current
56. oudage 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 e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur 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 Lire et comprendre les sp cifications de s curit des mat riaux MSDS et a tension constante a fil 2 un poste a 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 seulemen
57. 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 elements can give off toxic fumes if welded OM 222 394 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 e 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 749 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 fly
58. pressed 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 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 222 394 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
59. se la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct nor Shireen ler reparercer appareil e 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 e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl e E UNE DECHARGE ELECTRIQUE peut e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le 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 provoquer des accidents mortels ou des br lures e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est q p sous tension lorsque le courant est d livr la M ER sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le cable de retour de fa on obtenir un bon contact metal metal 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
60. ses When welding the display shows actual voltage The display will show actual voltage for approximately 3 seconds after welding stops before returning to preset value 2 Upper Display Push Button Press the button to illuminate the LED and allow changing information in the display 3 Upper Display Push Button LED The upper display push button LED OM 222 394 Page 20 O Arc Adjust illuminates to indicate that information displayed can be changed by the Adjust knob 4 Volts LED Indicates a voltage value is being displayed preset voltage in MIG when not welding and actual voltage while welding 5 Arc Adjust LED Indicates that displayed value is an arc length value when the process is Pulse Accu pulse or RMD optional At any time while welding the display allows adjustment of the weld voltage or arc adjust preset values by turning the Adjust knob The preset values will be displayed while the knob is being rotated and return to displaying actual values when adjustment is completed To activate Carbon Arc Gouging CAC press and hold the upper display push button in on power up CAC will appear on the upper dis play and NO will appear on the lower display Rotate adjust knob to YES on the lower dis play and press the flashing Feeder Set up push button CYCL will appear on the upper display and PWR will appear on the lower dis play Turn welding power source off and back on again to enable the Carbon
61. 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 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 cables 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 222 394 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 Recommende
62. stflow times and parameters Setting a time value for gas flow prior to arc start Provides voltage arc adjust wire feed rate and time value for modified arc starts which is only adjustable with the optional PDA with File Management WaveWriter software Allows setting of voltage arc adjust wire feed rate and time value for arc ends Setting a time value for gas flow after arc end Allow selection of Sequence and trigger functions Method of jogging wire without holding jog or trigger switch Pressing Jog and Retract simultaneously will automatically feed wire Default setting is 192 at a feed rate of 700 ipm these values can be changed using a PDA with File Management WaveWriter software Pressing jog purge or trigger switch will terminate the auto threading feature SECTION 6 OPERATION 6 1 Power Switch 1 Power Switch 804 021 A 1 Left Right Select Switch Pressing the Left Right Select switch allows the operator to choose which side of the units con trols will operate Depressing the Left or Right Gun Trigger also allows the operator to enable the con trols on that side of the unit 804 022 A OM 222 394 Page 17 6 3 Jog Purge The Jog Purge switch provides the following functions e Pressing left side of the Jog Purge switch allows the operator to feed wire without energizing the weld power or gas valve circuit The wire will feed at a 60 ipm rate for 3 seconds then the rate ramps up t
63. t 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 e 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 niveau 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 operations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulverisation La chaleur et les rayons de provinciales et locales Parc peuvent r agir en presence de vapeurs et former des gaz haute zl ment toxiques et irritants e Toujours verifier 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 En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexio
64. 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 GQ Miller Effective January 1 2006 Equipment with a serial number preface of LG 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 w
65. u 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 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 222 394 Page 6 LES ACCUMULATIONS DE GAZ risquent d
66. ues 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 curit les dangers 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce manuel e 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 entra ner la mort instructions aff rentes pour viter tout risque Les instructions en e 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 e Ne 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 raie e de dans la Section 2 5 Lire et amp Ne pas enrouler les c bles autour du corps id DUM i e Sila pi ce soud e doit tre mi
67. ve when Program Lock is enabled The reset mode allows the operator to reload factory program settings for all eight active programs in the unit System configuration data will be lost during the Reset operation Program O Volts 0 Arc Length JA WireSpeed Amps Process e Wireteed Wire Type Gas Gas Type C Contactor Adjust Arc Control Cycl Pwr message appears on the display when programs complete loading Turn power off wait 10 seconds and turn power back on again to complete the reset operation After Reset is complete be sure to load appropriate programs that contain the correct wire size process and shielding gas for the welding operation 198 993 803 246 B SECTION 7 SETTING SEQUENCE PARAMETERS 7 1 Sequence Parameters In A Program 6 8 For more information on Sequence mode see Feeder Set Up Push Button in Section Weld Time can only be set by using Sequence Parameters an optional PDA with File Management WaveWriter software Volts Arc IPM Seconds If time is set to zero in any timed Adjust sequence the sequence is skipped 1 Preflow Off 5 0 Maximum IPM may actually be and wire type selection 2 Postflow Off 5 0 10 0 44 0 40 1400 10 0 44 0 40 1400 pee Preflow Postflow Time Time Preflow Start Weld Crater Postflow ne Trigger Trigger Pressed Released lower depending on the process OM 222 394 Page 25
68. wer 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 input 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
69. wire before stopping The default feed rate is 700 ipm These settings can be changed using an optional PDA with File Management WaveWriter software 6 4 Front Panel Sections See Section Program 6 5 Process Wire Type Gas Type Section Section 6 10 6 9 Trigger Control 9 Trigger Hold a Feeder Set Up Section 6 8 Section Section OM 222 394 Page 19 6 5 Program Push Button 6 6 Upper Display n E Program T dn y N 1 Program Display The number of the active program is displayed 2 Program Push Button 3 Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob Momentarily press button to illuminate LED To change the program number rotate Adjust knob to select one of eight programs Pressing and holding the push button will display the program name Current wire size wire type and process To retrieve the original eight factory default programs press and hold button in on power up Top display will show RST bottom display will show NO and Feeder Set Up button LED will be flashing Turn Adjust control to change bottom display to show YES then press Feeder Set Up button to confirm selection Continue by allowing feeder to proceed with power up _ C Volts 1 UpperDisplay The upper display at idle not welding shows preset volts with process selection MIG or Arc Adjust for all other proces
70. x 619 OD x 105 2 TO NITE 133 493 RING retaining ext 250 shaft x 025thk 2 WE E nn 199 OOO x PIN DINGO ca SR MR aZ aras D dte Ead quale aasma W ana Re c a ee 1 ds Jones IM 2 ay Z 215 005 i MOTOR OO isidro ie Re at 1 NT EE e 203 631 PRESSURE ARM consisting of ler saus ces 1824157 a PIN COMER Tall s Gi nite tinte te Ne oder ee Sew nod Us 1 AAA 203 640 KNOB w extension short pressure arm 1 bas em cre amas us 203 641 2 WASHER flat SI SAENO 8 osi EE dara ia ag ista 2 ra ue nee 182156 saa SPRING ODS M 191 pata hich bet iu ut isa 2 x NE LERTE e et s URS 182 19D sci SPRING A ukupa QS M sqa ma Mol s 2 ON io ONERE CNN 192 746 BUSBIN G SDEFIG 3 2 3 as sas daten ede rab a umts eae Sims nee 2 natas dee diis aise 203 633 band RAE SDN Aire bakal cA dne aiunt ad cee damn Dd Shed 1 eur ane rM 203 532 sra CARRIER Shall ned terit a mi aku a aa meme dus 1 je MB ana oy O 133 739 WASHER flat buna 375 ID x 625 OD x 062thk 2 bl DR 203 637 KNOB w extension long pressure arm 1 PEPE E ee 229 550 ENCODER quadrature 500PPR incremental 5V shaftless 1 habui toa atados uod fate 604 311 GROMMET rbr 250 ID x 375mtg hole 062 groove 1 Ui ADAM UA EINE DL A 603 115 WEATHER STRIPPING adh 125 x 375
71. x 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 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
72. ylinders 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 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

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