Miller Electric Auto Axcess 675 Users Manual O201540k_mil

Auto Axcess 675 to the manual 5246f680-aa6e-441d-8318-8e6ec479ab53

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OM-201 540K 2007−10

Auto Axcess 675

Processes

Description

MIG (GMAW) Welding

Pulsed MIG (GMAW-P)

Flux Cored (FCAW) Welding

Automatic Welding

Automatic Welding Interface And

Arc Welding Power Source

™

File: Advanced Manufacturing Systems

Visit our website at

www.MillerWelds.com/ams

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.

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.

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

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001:2000 Quality

System Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 4/05

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symboles utilisés 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . .

2-4. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Principales normes de sécurité 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Information EMF 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions And Weight 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Duty Cycle And Overheating 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Volt-Ampere Curves 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Selecting A Location 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Connection Diagram 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Rear Panel Receptacles And Supplementary Protectors 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Connecting To Weld Terminals 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Selecting Weld Cable Sizes* 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Peripheral Receptacle Functions 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Motor Control Receptacle Functions 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Electrical Service Guide 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Connecting Input Power 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Touch Sensor Operation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15. Remote Program Select 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16. Remote Program Setting 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Operational Terms 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Front Panel Controls (See Section 4-3) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Front Panel Controls - Continued (See Section 4-2) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Front Panel Switches 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Robot Calibration Mode 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Robot Auto-Calibration Sample Programs 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Reset Mode 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Blowing Out Inside Of Unit 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Symbol Usage 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Servicing Hazards 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. California Proposition 65 Warnings 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. EMF Information 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 7 − TROUBLESHOOTING 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Set Value Mode 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Diagnostics 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Removing Cover and Measuring Input Capacitor Voltage 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Process Control Module PC4 Diagnostic LED’s 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Diagnostic LED’s On Process Control Module PC4 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings 39 . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Diagnostic LED’s On Wire Feed Module PC6 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. User Interface Module PC7 Diagnostic LED’s 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Diagnostic LED’s On User Interface Module PC7 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Automation Interface Module PC9 Diagnostic LED’s 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11. Diagnostic LED’s On Automation Interface Module PC9 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12. Network And Module Status LED’s 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13. Troubleshooting 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAMS 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-201 540 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _2007−04

7

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

.Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

DDo not touch live electrical parts.

DWear dry, hole-free insulating gloves and body protection.

DInsulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

DDo not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

DUse AC output ONLY if required for the welding process.

DIf AC output is required, use remote output control if present on

unit.

DAdditional 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!

DDisconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

DProperly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

DAlways 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.

DWhen making input connections, attach proper grounding conduc-

tor first − double-check connections.

DKeep cords dry, free of oil and grease, and protected from hot metal

and sparks.

DFrequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

DTurn off all equipment when not in use.

DDo not use worn, damaged, undersized, or poorly spliced cables.

DDo not drape cables over your body.

DIf earth grounding of the workpiece is required, ground it directly

with a separate cable.

DDo not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

DDo not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

DUse only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

DWear a safety harness if working above floor level.

DKeep all panels and covers securely in place.

DClamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

DInsulate work clamp when not connected to workpiece to prevent

contact with any metal object.

DDo 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.

DTurn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllow cooling period before working on gun or

torch.

DTo handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

OM-201 540 Page 2

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

DKeep your head out of the fumes. Do not breathe the fumes.

DIf inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

DIf ventilation is poor, wear an approved air-supplied respirator.

DRead and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

DWork in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

DDo 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.

DDo not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

Arc rays 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.

ARC RAYS can burn eyes and skin.

DWear an approved welding helmet fitted with a proper shade of fil-

ter lenses to protect your face and eyes when welding or watching

(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

DWear approved safety glasses with side shields under your

helmet.

DUse protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

DWear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

DRemove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

DDo not weld where flying sparks can strike flammable material.

DProtect yourself and others from flying sparks and hot metal.

DBe alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

DWatch for fire, and keep a fire extinguisher nearby.

DBe aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

DDo not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

DDo not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

DConnect 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.

DDo not use welder to thaw frozen pipes.

DRemove stick electrode from holder or cut off welding wire at

contact tip when not in use.

DWear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

DRemove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

DAfter completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

DUse only correct fuses or circuit breakers. Do not oversize or by-

pass them.

DFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

DWelding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

DWear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

DShut off shielding gas supply when not in use.

DAlways ventilate confined spaces or use

approved air-supplied respirator.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

DWearers of Pacemakers and other Implante

d

Medical Devices should keep away.

DImplanted Medical Device wearers should consult their docto

r

and the device manufacturer before going near arc welding, spo

t

welding, gouging, plasma arc cutting, or induction heating

operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

DWear approved ear protection if noise level is

high.

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.

CYLINDERS can explode if damaged.

DProtect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

DInstall cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

DKeep cylinders away from any welding or other electrical circuits.

DNever drape a welding torch over a gas cylinder.

DNever allow a welding electrode to touch any cylinder.

DNever weld on a pressurized cylinder − explosion will result.

DUse only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

DTurn face away from valve outlet when opening cylinder valve.

DKeep protective cap in place over valve except when cylinder is in

use or connected for use.

DUse the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

DRead and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-201 540 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

DDo not install or place unit on, over, or near

combustible surfaces.

DDo not install unit near flammables.

DDo not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

DUse equipment of adequate capacity to lift and

support unit.

DIf using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before

starting to weld again.

DDo not block or filter airflow to unit.

FLYING SPARKS can cause injury.

DWear a face shield to protect eyes and face.

DShape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

DSparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

DUse proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

DKeep away from moving parts.

DKeep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

DDo not press gun trigger until instructed to do

so.

DDo not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

DKeep away from moving parts such as fans.

DKeep all doors, panels, covers, and guards

closed and securely in place.

DHave only qualified persons remove doors, panels, covers, or

guards for maintenance as necessary.

DReinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

DRead Owner’s Manual before using or servic-

ing unit.

DUse only genuine replacement parts from the

manufacturer.

H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

DHave only qualified persons familiar with

electronic equipment perform this installation.

DThe user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

DIf notified by the FCC about interference, stop using the

equipment at once.

DHave the installation regularly checked and maintained.

DKeep 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.

DElectromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

DBe sure all equipment in the welding area is

electromagnetically compatible.

DTo reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

DLocate welding operation 100 meters from any sensitive elec-

tronic equipment.

DBe sure this welding machine is installed and grounded

according to this manual.

DIf interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

OM-201 540 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

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, Quincy, MA 02269-9101 (phone:

617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 5060 Mississauga,

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:

212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-

site: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for

Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-6. 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

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

OM-201 540 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

fre_som_2007−04

7

Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on

l’évite pas peut donner la mort ou des blessures graves.

Les dangers possibles sont montrés par les symboles

joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas

peut donner la mort ou des blessures graves. Les dan-

gers possibles sont montrés par les symboles joints ou

sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures

personnelles.

.Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES

CHAUDES. Consulter les symboles et les instructions ci-dessous y

afférant pour les actions nécessaires afin d’éviter le danger.

2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce ma-

nuel pour attirer l’attention et identifier les dangers possibles. En

présence de l’un de ces symboles, prendre garde et suivre les

instructions afférentes pour éviter tout risque. Les instructions

en matière de sécurité indiquées ci-dessous ne constituent

qu’un sommaire des instructions de sécurité plus complètes

fournies dans les normes de sécurité énumérées dans la Sec-

tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc-

tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les

personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut

entraîner la mort.

Le contact d’organes électriques sous tension peut

provoquer des accidents mortels ou des brûlures

graves. Le circuit de l’électrode et de la pièce est

sous tension lorsque le courant est délivré à la

sortie. Le circuit d’alimentation et les circuits internes de la machine

sont également sous tension lorsque l’alimentation est sur Marche.

Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de

commande du rouleau et toutes les parties métalliques en contact

avec le fil sont sous tension électrique. Un équipement installé ou mis

à la terre de manière incorrecte ou impropre constitue un danger.

DNe pas toucher aux pièces électriques sous tension.

DPorter des gants isolants et des vêtements de protection secs et

sans trous.

DS’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la

pièce à couper ou le sol.

DNe pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de

tomber.

DSe servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

DSi l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil

en est équipé.

DD’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement

humide ou si l’on porte des vêtements mouillés ; sur des structures

métalliques telles que sols, grilles ou échafaudages ; en position

coincée comme assise, à genoux ou couchée ; ou s’il y a un risque

élevé de contact inévitable ou accidentel avec la pièce à souder ou

le sol. Dans ces conditions, utiliser les équipements suivants,

dans l’ordre indiqué : 1) un poste à souder DC à tension constante

(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à

souder AC à tension à vide réduite. Dans la plupart des situations,

l’utilisation d’un poste à souder DC à fil à tension constante est re-

commandée. En outre, ne pas travailler seul !

DCouper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller

l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-

mes de sécurité).

DInstaller le poste correctement et le mettre à la terre convenable-

ment selon les consignes du manuel de l’opérateur et les normes

nationales, provinciales et locales.

DToujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien

raccordé à la borne de terre du sectionneur ou que la fiche du

cordon est raccordée à une prise correctement mise à la terre.

DEn effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

DLes câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques

chaudes.

DVérifier fréquemment le cordon d’alimentation afin de s’assurer

qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.

Un fil à nu peut entraîner la mort.

DL’équipement doit être hors tension lorsqu’il n’est pas utilisé.

DNe pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

DNe pas enrouler les câbles autour du corps.

DSi la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

DNe pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

DNe pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou-

blée.

DN’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil

conformément à ce manuel.

DPorter un harnais de sécurité si l’on doit travailler au-dessus du sol.

DS’assurer que tous les panneaux et couvercles sont correctement

en place.

DFixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près

possible de la soudure.

DIsoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

DNe pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage.

OM-201 540 Page 6

Il reste une TENSION DC NON NÉGLIGEABLE dans

les sources de soudage onduleur quand on a

coupé l’alimentation.

DArrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions

indiquées dans la partie Entretien avant de toucher les pièces.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

DNe pas toucher à mains nues les parti

es

chaudes.

DPrévoir une période de refroidissement avant

de

travailler à l’équipement.

DNe pas toucher aux pièces chaudes, utiliser les outils recomma

n-

dés et porter des gants de soudage et des vêtements épais po

ur

éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent ê

tre

dangereux.

Le soudage génère des fumées et des gaz. Leu

r

inhalation peut être dangereux pour votre santé.

DEloigner votre tête des fumées. Ne pas respirer les fumées.

DÀ l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

DSi la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

DLire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les

consommables, les revêtements, les nettoyants et les dégrais-

seurs.

DTravailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à

un surveillant dûment formé de se tenir à proximité. Des fumées et

des gaz de soudage peuvent déplacer l’air et abaisser le niveau

d’oxygène provoquant des blessures ou des accidents mortels.

S’assurer que l’air de respiration ne présente aucun danger.

DNe pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et

les rayons de l’arc peuvent réagir en présence de vapeurs et for-

mer des gaz hautement toxiques et irritants.

DNe pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête-

ment n’ait été enlevé dans la zone de soudure, que l’endroit soit

bien ventilé, et en portant un respirateur à alimentation d’air. Les

revêtements et tous les métaux renfermant ces éléments peuvent

dégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuven

t

provoquer des brûlures dans les

yeux et sur la peau.

Le rayonnement de l’arc du procédé de souda

ge

génère des rayons visibles et invisibles intens

es

(ultraviolets et infrarouges) susceptibles de provoquer des brûlu

res

dans les yeux et sur la peau. Des étincelles sont projetées pendan

t le

soudage.

DPorter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage

(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

DPorter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

DAvoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements

et les étincelles ; prévenir toute personne sur les lieux de ne pas

regarder l’arc.

DPorter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de

protection.

LE SOUDAGE peut provoquer un

in-

cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés t

els

que des réservoirs, tambours ou des conduites p

eu

provoquer leur éclatement. Des étincelles peuv

en

être projetées de l’arc de soudure. La projection d’étincelles, des pièc

es

chaudes et des équipements chauds peut provoquer des incendies

e

des brûlures. Le contact accidentel de l’électrode avec des obj

ets

métalliques peut provoquer des étincelles, une explosion, un surcha

uf-

fement ou un incendie. Avant de commencer le soudage, vérifier

e

s’assurer que l’endroit ne présente pas de danger.

DDéplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir

soigneusement avec des protections homologués.

DNe pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

DSe protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

DDes étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites

fissures et des ouvertures.

DSurveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

DLe soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

DNe pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été

préparés correctement conformément à AWS F4.1 (voir les nor-

mes de sécurité).

DNe soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

DBrancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une

longue distance par des chemins inconnus éventuels en provo-

quant des risques d’électrocution, d’étincelles et d’incendie.

DNe pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

DEn cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

DPorter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans

revers, des chaussures hautes et un couvre chef.

DAvant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

DUne fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

DUtiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

DUne fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

DUtiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

DSuivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un

extincteur à proximité.

DES PIECES DE METAL ou DES

SALETES peuvent provoquer des

blessures dans les yeux.

DLe soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules

métalliques volantes. Pendant la période de refroidissement des

soudures, elles risquent de projeter du laitier.

DPorter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

OM-201 540 Page 7

LES ACCUMULATIONS DE GAZ

risquent de provoquer des blessures

ou même la mort.

DFermer l’alimentation du gaz protecteur en cas

de non-utilisation.

DVeiller toujours à bien aérer les espaces confi-

nés ou se servir d’un respirateur d’adduction

d’air homologué.

LES CHAMPS MAGNETIQUES peuv-

ent affecter des implants médicaux.

DPorteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

DLes porteurs d’implants doivent d’abord consulter leur médecin

avant de s’approcher des opérations de soudage à l’arc, de sou-

dage par points, de gougeage, du coupage plasma ou de chauf-

fage par induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut

affecter l’ouïe.

DPorter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

Des bouteilles de gaz protecteur contiennent du gaz

sous haute pression. Si une bouteille est endomma-

gée, elle peut exploser. Du fait que les bouteilles de

gaz font normalement partie du procédé de sou-

dage, les manipuler avec précaution.

LES BOUTEILLES peuvent exploser

si elles sont endommagées.

DProtéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des

flammes ouvertes, des étincelles et des arcs.

DPlacer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou

de se renverser.

DTenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

DNe jamais placer une torche de soudage sur une bouteille à gaz.

DUne électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

DNe jamais souder une bouteille pressurisée − risque d’explosion.

DUtiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique ;

les maintenir ainsi que les éléments associés en bon état.

DDétourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

DLe couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

DUtiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

DLire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed

Gas Association) mentionné dans les principales normes de sécu-

rité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanc

e

Risque D’INCENDIE OU D’EXPLO-

SION.

DNe pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

DNe pas installer l’appareil à proximité de pro-

duits inflammables.

DNe pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant

de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut

blesser.

DUtiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les

bouteilles de gaz ou tout autre accessoire.

DUtiliser un équipement de levage de capacité

suffisante pour lever l’appareil.

DEn utilisant des fourches de levage pour déplacer l’unité, s’assu-

rer que les fourches sont suffisamment longues pour dépasser

du côté opposé de l’appareil.

L’EMPLOI EXCESSIF peut SUR-

CHAUFFER L’ÉQUIPEMENT.

DPrévoir une période de refroidissement ; re-

specter le cycle opératoire nominal.

DRéduire le courant ou le facteur de marche

avant de poursuivre le soudage.

DNe pas obstruer les passages d’air du poste.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

DPorter un écran facial pour protéger le visage

et

les yeux.

DAffûter l’électrode au tungstène uniquement à

la

meuleuse dotée de protecteurs. Cette manœu

v-

re est à exécuter dans un endroit sûr lorsque l’

on

porte l’équipement homologué de protection

du

visage, des mains et du corps.

DLes étincelles risquent de causer un incendie − éloigner toute su

b-

stance inflammable.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

DÉtablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

DUtiliser des pochettes et des boîtes antistati-

ques pour stocker, déplacer ou expédier des

cartes de circuits imprimes.

DES ORGANES MOBILES peuvent

provoquer des blessures.

DNe pas s’approcher des organes mobiles.

DNe pas s’approcher des points de coincement

tels que des rouleaux de commande.

OM-201 540 Page 8

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

DNe pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

DNe pas diriger le pistolet vers soi, d’autres per-

sonnes ou toute pièce mécanique en enga-

geant le fil de soudage.

DES ORGANES MOBILES peuvent

provoquer des blessures.

DS’abstenir de toucher des organes mobiles tels

que des ventilateurs.

DMaintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protec-

tion.

DSeules des personnes qualifiées sont autorisées à enlever les

portes, panneaux, recouvrements ou dispositifs de protection

pour l’entretien.

DRemettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher

l’alimentation électrique.

LIRE LES INSTRUCTIONS.

DLisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

DN’utiliser que les pièces de rechange recom-

mandées par le constructeur.

DEffectuer régulièrement le contrôle et l’entretien de l’installation.

DMaintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan-

ce correcte et utiliser une terre et un blindage pour réduire les

interférences éventuelles.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

DLe rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipe-

ments de radio−navigation et de communica-

tion, les services de sécurité et les ordinateurs.

DDemander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa-

tion.

DL’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

DSi le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

DL’énergie électromagnétique risque de provo-

quer des interférences pour l’équipement élec-

tronique sensible tel que les ordinateurs et l’é-

quipement commandé par ordinateur tel que

les robots.

DVeiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

DPour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser

aussi bas que possible (ex. par terre).

DVeiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

DVeiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

DEn cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé-

mentaires telles que le déplacement du poste, l’utilisation de câ-

bles blindés, l’utilisation de filtres de ligne ou la pose de protec-

teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des

fumées et des gaz qui contiennent des produits chimiques

dont l’État de Californie reconnaît qu’ils provoquent des mal-

formations congénitales et, dans certains cas, des cancers.

(Code de santé et de sécurité de Californie, chapitre 25249.5

et suivants)

Les batteries, les bornes et autres accessoires contiennent

du plomb et des composés à base de plomb, produits chimi-

ques dont l’État de Californie reconnaît qu’ils provoquent des

cancers et des malformations congénitales ou autres

problèmes de procréation. Se laver les mains après manipu-

lation.

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des pro-

duits chimiques dont l’État de Californie reconnaît qu’ils

provoquent des cancers et des malformations congénitales

ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de

leurs composants sont reconnus par l’État de Californie com-

me provoquant des cancers et des malformations

congénitales ou autres problèmes de procréation.

OM-201 540 Page 9

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 1-877-413-5184, site

Internet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone :

1-877-413-5184, site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :

617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-

tilly, VA 20151 (téléphone : 703-788-2700, site Internet :

www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de

Canadian Standards Association, 5060 Mississauga, Ontario, Canada

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site

Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :

212-642-4900, site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,

site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-

ne de la région 5, Chicago, est 312-353-2220, site Internet :

www.osha.gov).

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des

champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir exa-

miné plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National

Research Council a conclu : « L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine ». Toutefois, des études sont toujours en

cours et les preuves continuent à être examinées. En attendant que les

conclusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer

les procédures suivantes :

1. Garder les câbles ensemble, les torsader, les scotcher, ou les

recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4. Garder le poste de soudage et les câbles le plus loin possible de

vous.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant

de s’approcher des opérations de soudage à l’arc, de soudage par

points, de gougeage, du coupage plasma ou de chauffage par induc-

tion. Si le médecin approuve, il est recommandé de suivre les

procédures précédentes.

OM-201 540 Page 10

OM-201 540 Page 11

SECTION 3 − INSTALLATION

.Appearance of actual unit may vary from unit shown in manual.

3-1. Specifications

Input

Power

Rated

Welding

Output

Voltage

Range

Wire Feed

Speed

Range**

Wire

Diameter

Range

Max

Open

Circuit

Voltage

Amperes Input At Rated Load Output 60 Hz,

Three-Phase Input

KVA

Input

KW

Power

Welding

Output

Range

Speed

Range**

Diameter

Range

Circuit

Voltage

DC 230 V 400V 460 V 575 V

KVA

KW

Three

Phase 675 A @

44 V DC,

100%

Duty

Cycle

10-44 Standard:

50-1400

ipm

(1.3-35.6

mpm)

.035-.062 in

(0.8-1.6 mm) 85 89.7

(0-1A*) 52.0

(0-1A*) 43.7

(0-1A*) 21.2

(0-1A*) 35.7

(0.8*) 34.4

(0.17*)

*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.

**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.

3-2. Dimensions And Weight

Hole Layout Dimensions

A

E

22 in

A 17-3/32 in (434 mm)

A22 in

(559 mm)

B17-3/8 in (441 mm)

C19-3/32 in (485 mm) 41 in

(1041 mm)

D16-3/32 in (409 mm) B

C

(1041 mm)

E1/2 in (13 mm)

Weight

215 lb (98 kg) Net

232 lb (105 kg) Ship DRef. 802 913-B

15-1/2 in

(394 mm)

OM-201 540 Page 12

3-3. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

duty cycle before welding.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

Overheating 0

15

A/V

OR

Reduce Duty Cycle

Minutes

duty1 4/95 − 206 789-A

Continuous Welding

100% Duty Cycle At 675 Amperes

3-4. Volt-Ampere Curves

va_curve1 4/95 − 221 502-A

Volt-ampere curves show minimum

and maximum voltage and amper-

age output capabilities of unit.

Curves of other settings fall be-

tween curves shown.

.This volt-ampere curve repre-

sents the dynamic output of the

unit with a static load.

0

10

20

30

40

50

60

70

80

0 100 200 300 400 500 600 700 800 900 1000

CV MODE

VOLTAGE

AMPERES

OM-201 540 Page 13

3-5. Selecting A Location

loc_2 3/96 -Ref. 802 913-B

!Do not stack units. Beware of

tipping.

1 Lifting Forks

Use lifting forks to move unit.

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

Locate unit near correct input

power supply.

Movement

2

Location

4

18 in

(460 mm)

18 in

(460 mm)

3

Tipping

1

OR

!Do not move or operate

unit where it could tip.

!Special installation may be required where gasoline or volatile

liquids are present − see NEC Article 511 or CEC Section 20.

Ref. 802 913-B / Ref. 801 915-A

.The proper interface kit must

be installed in the welding pow-

er source/interface unit to allow

it to be connected to the robot.

1 Robot (Will Vary According To

Application)

2 Motor/Drive Assembly

3 Gas Cylinder

4 Gas Hose

5 Robot Control

6 Robot Input/Output Cable

7 Gas And Motor Control Cable

8 Welding Power

Source/Interface Unit

9 Negative (−) Weld Cable

10 Workpiece

11 Voltage Sensing Lead

(Optional)

.Positive (+) voltage sensing

lead is contained in the motor

cable.

12 Positive (+) Weld Cable

3-6. Connection Diagram

1

2 3

4

5

7

6

8

9

10

11

12

OM-201 540 Page 14

Ref. 802 915-A

1 115 V 10 A AC Receptacle RC2

Receptacle supplies 60 Hz

single-phase power. Maximum output

from RC2 is limited by supplementary

protector CB1 to 10 amps.

2 Supplementary Protector CB1

3 Supplementary Protector CB2

CB1 protects 115 volt receptacle RC2

from overload. If CB1 opens, RC2 does

not work.

CB2 protects the wirefeed motor from

overload. If CB2 opens, the wirefeeder

does not work.

.Press button to reset breaker. If

breaker continue to open, contact a

Factory Authorized Service Agent.

4 Wirefeed/Gas Receptacle RC8

Use receptacle to connect gas and

motor control cable to power source

(see Sections 3-6 and 8 for additional

information).

5 Peripheral Receptacle RC25

Receptacle provides connection to

touch sensor, water flow switch, jog +/−,

and I/O relay contacts circuitry (see

Section 3-10).

6 Robot Interface Receptacle RC72

Use receptacle to connect robot

input/output cable (see Sections 3-6

and 8 for additional information).

2

3

3-7. Rear Panel Receptacles And Supplementary Protectors

1

645

OM-201 540 Page 15

3-8. Connecting To Weld Terminals

Ref. 802 913-B / 803 778-A

1

2

Tools Needed:

3/4 in (19mm)

6

4

5

Do not place

anything between

3

weld cable terminal

and copper bar.

Correct Installation Incorrect Installation

!Turn off power before connecting to

weld output terminals.

!Failure to properly connect weld

cables may cause excessive heat

and start a fire, or damage your

machine.

Determine total cable length in weld circuit

(both positive and negative cables

combined) and maximum welding

amperes. See Section 3-10 to select proper

cable size.

1 Positive (+) Weld Output Terminal

2 Negative (−) Weld Output Terminal

Connect positive weld cable to Positive (+)

weld terminal and negative (−) cable to

Negative weld terminal.

3 Weld Output Terminal

4 Supplied Weld Output Terminal Nut

5 Weld Cable Terminal

6 Copper Bar

Remove supplied nut from weld output

terminal. Slide weld cable terminal onto

weld output terminal and secure with nut so

that weld cable terminal is tight against

copper bar. Do not place anything

between weld cable terminal and copper

bar. Make sure that the surfaces of the

weld cable terminal and copper bar are

clean.

.If using an electrode negative (straight polarity)

process, the volt sense lead must be connected

to the work.

OM-201 540 Page 16

3-9. Selecting Weld Cable Sizes*

!ARC WELDING can cause Electromagnetic Interference.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed

and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving

the welding machine, using shielded cables, using line filters, or shielding the work area.

Weld Cable Size*** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding****

100 ft (30 m) or Less 150 ft

(45 m) 200 ft

(60 m) 250 ft

(70 m) 300 ft

(90 m)

350 ft

(105

m)

400 ft

(120

m)

Weld Output

Terminals

!Turn off power before

connecting to weld

output terminals.

!Do not use worn, dam-

aged, undersized, or

poorly spliced cables.

Welding

Amperes**

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle 10 − 100% Duty Cycle

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0

(120) 4/0

(120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0

(120) 2 ea. 2/0

(2x70) 2 ea. 2/0

(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0

(120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 3/0

(2x95)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0

(120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0

(120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 2 ea. 4/0

(2x120)

500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 3/0

(3x95) 3 ea. 3/0

(3x95)

600 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 3/0

(3x95) 3 ea. 4/0

(3x120) 3 ea. 4/0

(3x120)

700 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 3/0

(3x95) 3 ea. 4/0

(3x120) 3 ea. 4/0

(3x120) 4 ea. 4/0

(4x120)

Positive Negative

800 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 4/0

(3x120) 3 ea. 4/0

(3x120) 4 ea. 4/0

(4x120) 4 ea. 4/0

(4x120)

Positive

)

Negative

*

Ref. 802 914-B

900 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 3/0

(3x95)

Ref. 802 914-B

1000 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 3/0

(3x95)

1250 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 3/0

(3x95) 4 ea. 3/0

(4x95)

* This chart is a general guideline and may not suit all applications. If cable overheating occurs, use next size larger cable.

**Cable should be sized for Peak Amperage (Apk) for pulse welding applications.

***Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm2 for metric use

****For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. S-0007-E

.In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding characteris-

tics with undersized cables. A recommendation for weld cable size is a minimum of 2/0 for 300 ampere welding power sources and 4/0 for 450

ampere welding power sources when total cable length is less than 100 ft (30m).

OM-201 540 Page 17

3-10. Peripheral Receptacle Functions

B

C

Function Socket Socket Information

A

B

C

L

DANot used.

K

M

J

L

E

F

BNot used.

K

J

H

F

C* Circuit common.

Purge DContact closure to C completes 40 volts dc

solenoid circuit to purge shielding gas line.

Coolant Flow

Switch Input

Signal

EContact closure to F indicates coolant flow switch is

closed and recirculating coolant system is

operational.

Signal

F* Circuit common.

Jog H** Contact closure to circuit common advances

welding wire at wire drive assembly.

Retract J** Contact closure to circuit common retracts welding

wire at wire drive assembly.

KContact closure to L energizes Touch Sensor

circuitry.

Touch Sensor ON

And Output Signa

l

L* Circuit common.

Ref. 802 915-A

And Output Signal

MPart touched +24 volts dc output signal referenced

to circuit common.

*Circuit common is same electrical reference point.

**Speed of Jog + (advance) and Jog − (retract) is 60 ipm for 3 seconds, then it automatically changes to 700 ipm.

Note: A customer supplied matching amphenol plug, factory Part No. 194 847, [Amphenol Part No. 97-3106A-20-33P(B)(621) and strain relief

clamp 97-3057-12(0621)] is required to use peripheral receptacle.

OM-201 540 Page 18

3-11. Motor Control Receptacle Functions

A

C

GSocket Socket Information

BE

K

F

J

A

G

ANot used.

D

H

BE

K

B Motor negative (−).

CTach A.

DMotor positive (+).

ETach common.

FGas valve.

GElectrode sense.

HTach +5 volts dc.

JTach B.

Ref. 802 915-A

KGas valve.

OM-201 540 Page 19

3-12. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-

tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of

input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-

tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

.Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not

be available.

60 Hz Three Phase

Input Voltage 230 400 460 575

Input Amperes At Rated Output 89.7 52.0 43.7 21.2

Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay 2110 60 50 40

Normal Operating 3125 80 70 50

Min Input Conductor Size In AWG 43 6 8 8

Max Recommended Input Conductor Length In Feet (Meters) 173

(53) 275

(84) 231

(70) 361

(110)

Min Grounding Conductor Size In AWG 46 8 8 10

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.

2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

OM-201 540 Page 20

3-13. Connecting Input Power

802 915-A / Ref. 803 766-A / 218 005-A

Tools Needed:

5/16 in

Route ground conductor through

current transducer to ground terminal.

Route input power cable

through tubing inside unit.

Three-Phase Input Connection

Read Owner’s Manual.

ELECTRIC SHOCK can kill;

SIGNIFICANT DC VOLTAGE

exists after removal of

input power.

S Always wait 5 minutes after power

Is turned off before working on unit.

S Check input capacitor voltage, and

be sure it is near 0 before touching

any parts.

WARNING

2

3

3

1

4

5

6

7

8

L1

L2

L3

= GND/PE Earth Ground

!Turn Off welding power source, and

check voltage on input capacitors

according to Section 7-3 before

proceeding.

!Installation must meet all National

and Local Codes − have only qualified

persons make this installation.

!Disconnect and lockout/tagout input

power before connecting input

conductors from unit.

!Make input power connections to the

welding power source first.

!Always connect green or

green/yellow conductor to supply

grounding terminal first, and never to

a line terminal.

1 Input Power Conductors (Customer

Supplied Cord)

Select size and length of conductors using

Section 3-12. Conductors must comply with

national, state, and local electrical codes. If

applicable, use lugs of proper amperage

capacity and correct hole size.

Welding Power Source Input Power

Connections

2 Strain Relief

Install strain relief of proper size for unit and

input conductors. Route conductors (cord)

through strain relief and tighten screws.

SUse large strain relief for input conductor

size 8 and larger.

SUse small strain relief with reducing

washers for input conductor size 10.

Connect input conductors as shown in

illustration.

Route green or green/yellow grounding

conductor through current transducer and

connect to welding power source grounding

terminal first. Then connect input conductors

L1, L2, and L3 to welding power source line

terminals.

Reinstall side panel onto welding power

source.

Disconnect Device Input Power

Connections

3 Disconnect Device (switch shown in

the OFF position)

4 Green Or Green/Yellow Grounding

Conductor

5 Disconnect Device Grounding Terminal

6 Input Conductors (L1, L2 And L3)

7 Disconnect Device Line Terminals

Connect green or green/yellow grounding

conductor to disconnect device grounding

terminal first.

Connect input conductors L1, L2, and L3 to

disconnect device line terminals.

8 Over-Current Protection

Select type and size of over-current protec-

tion using Section 3-12 (fused disconnect

switch shown).

Close and secure door on disconnect device.

Remove lockout/tagout device, and place

switch in the On position.

OM-201 540 Page 21

3-14. Touch Sensor Operation

The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source.

The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral

receptacle. Turning on touch sensor causes a dc voltage to be present on the welding wire. When welding wire

touches the weldment, the voltage sensing circuit closes, and a +24 volts dc output signal is sent to the robot control

indicating weldment detection. Touch sensor dc voltage on the welding wire is 80 volts DC. As soon as touch sensor

turns on, WIRE LIVE appears on the front panel display.

3-15. Remote Program Select

.Remote Program Select is factory set to “On”. WaveWriter or File Management software is required to turn this function “Off”.

When Remote Program Select is On, a remote device or robot pendant may be used to select programs. When Off,

program selection must be done from the welding power source front panel.

3-16. Remote Program Setting

.When Remote Program Select is “On”, program selection will be determined by remote input once a weld is initiated. Prior to welding, program

selection can be done in a normal manner from the welding power source front control panel.

See the following table for the remote program select binary code.

Program No. Output A Output B Output C

1 Off Off Off

2 On Off Off

3 Off On Off

4 On On Off

5 Off Off On

6 On Off On

7 Off On On

8 On On On

OM-201 540 Page 22

SECTION 4 − OPERATION

4-1. Operational Terms

The following is a list of terms and their definitions as they apply to this interface unit:

General Terms:

Synergic Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual pulse

settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed

speed setting.

Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual

arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by volts in MIG

programs.

Program Eight active slots for selection of various processes, wire types, and parameters.

Process A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).

MIG CV weld process with individual settings of voltage and wire speed.

Pulse Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory

taught data. Adaptive method is controlled by frequency adjustment.

Accu-pulse 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.

Accuspeed CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is designed to be

tight and fast. Front panel display is ACCU − SPED.

AccuCurve CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform. Has

a distinguished change in arc characteristics. Front panel display is ACCU − CURV.

RMD (optional) 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.

Wire Type Selection of wire type by alloys and classification.

Gas Type Selection of shielding gas being used in application.

Process Set Up Selection procedure for entering program.

Program Load Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).

Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.

Time 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).

Arc Length Distance from end of wire electrode to workpiece.

WFS 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).

Amps Indicates average amperage while welding and 3 seconds hold value at end of weld.

Arc Control Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD

(optional).

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.

Sharp Arc 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 arc in much the same way as inductance.

Adjust Control knob used to change or set parameters and functions.

Sequence Selecting Sequence will allow setting of preflow, start, crater, postflow, and retract times and parameters (only

available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes).

Preflow Setting a time value for gas flow prior to arc start (only available on Auto Axcess models in the Arc On and

Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File

Management software).

OM-201 540 Page 23

4-1 . Operational Terms (Continued)

Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (only available on Auto Axcess

models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the

optional PDA with File Management software).

Weld Sequence function that allows for a timed weld operation [(0 to 999 seconds) only available on Auto Axcess

models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the

optional PDA with File Management software].

Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends (only available on Auto Axcess

models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the

optional PDA with File Management software).

Postflow Setting a time value for gas flow after arc end (only available on Auto Axcess models in the Arc On and Analog

input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File Manage-

ment software).

Retract Sequence function that allows the wire to move back towards the contact tip when a welding operation is

completed. Setting is both speed (IPM) and time (sec), (only available on Auto Axcess models in the Arc On

and Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File

Management software).

Auto Thread Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously will

automatically feed wire. Default setting is 72 inches at a feed rate of 700 ipm. Pressing jog, purge, or trigger

switch will terminate the auto-threading feature. These values can be changed using a PDA with File

Management/WaveWriter software.

OM-201 540 Page 24

4-2. Front Panel Controls (See Section 4-3)

Program

Process

Wire Type

Gas Type

Adjust

Volts Arc Adjust

Wire Speed Amps

Setup Arc Control

Wirefeed

Gas

Contactor

.When an LED is lit, it means the related function is active.

1 Program Display

Displays the number of the active program.

2 Adjust Knob

Turn the Adjust knob to change program

number, Setup, Arc Control, and weld

parameters.

3 Program Push Button LED

The LED lights when the Program Push

Button is active.

4 Program Push Button

Press push button (LED lights) and turn Adjust

knob to select active program.

The letter C is displayed with the program

number if the program has been changed from

the factory settings using the optional PDA

with File Management/WaveWriter software

(see File Management/WaveWriter Owner’s

Manual).

.The program cannot be changed through

the front panel while welding.

Press and hold button to see program name.

Custom programs are named using optional

PDA with File Management/WaveWriter

software. Program name is shown in upper

and lower displays (items 13 and 15).

5 Setup Mode Indicators

The lit LED indicates which setup mode is

active. Setup mode parameters are shown in

Display Windows (see Items 13 and 15).

Process LED

When this LED is lit, turn the Adjust knob to

select the desired weld process. Choices

include pulse welding (displayed as PULS),

Accu-pulse, MIG welding (MIG), and Accu

Puls/RMD [Regulated Metal Deposition

(optional)].

Wire Type LED

When this LED is lit, turn the Adjust knob to

select the desired wire type, wire alloy, and

size. Wire type and size choices vary

according to the selected weld process.

Choices may include steel (displayed as

STL), stainless steel (SS), metal core

(MCOR), aluminum (ALUM). See Table 4-1

for all wire abbreviations.

Gas Type LED

When this LED is lit, turn the Adjust knob to

select the desired weld gas. Gas type choices

vary according to the selected weld process.

See Table 4-1 for all gas abbreviations.

6 Setup Push Button LED

The LED lights to indicate one of the setup

modes is active.

7 Setup Push Button

Press button to select Process, Wire Type,

Wire Diameter, or Gas Type parameters.

.In order for selections to be retained in

memory, the Setup push button must be

pressed six times before any other push

button is pressed: once to select Process,

again to select Wire Type, again to select

Wire Alloy, again to select Wire Size,

again to select Gas Type, and a sixth time

to store selections in memory. The

displays will temporarily show “PROG

LOAD” to indicate the data is being stored

in memory.

198 993

1

2

3

4

5

6

7

8

9

10

11

12

13

1415

OM-201 540 Page 25

4-3. Front Panel Controls - Continued (See Section 4-2)

8 Arc Control LED

The LED lights to indicate the Arc Control

button is active. Light goes out when button is

inactive.

9 Arc Control Push Button

This push button allows fine tuning inductance

for MIG programs, and Arc Control for

programs other than MIG. When the push

button is pressed, the upper display (item 15)

shows INDU for inductance, or ARC for Arc

Control to indicate which parameter is

selected for change. The range of possible

values is 0-99 for inductance, and 0-50 for arc

control. Turn the Adjust knob to change the

parameter value. Press button to deactivate

arc control mode (LED goes out).

10 Wire Feed/Gas/Contactor LEDs

The Wirefeed LED lights when the wire feeder

is energized. For example, when the front

panel Jog or Retract button is pressed, the

Wirefeed LED lights.

The Gas LED lights when the gas valve is

energized.

The Contactor LED lights when the output

contactor is energized, making the weld

output terminals live.

11 Wire Speed And Amps LED’s

The lit LED indicates whether wire speed or

amps are being displayed.

12 Wire Feed Speed/Amps Display Push

Button

13 Lower Display

Press Wire Feed Speed/Amps Display button

to show weld amperage or wire feed speed in

lower display (the applicable LED under the

lower display lights to indicate which is

shown). When welding, actual value is shown.

If amperage was selected for display, the unit

will show actual welding amperage prior to

and while welding unless the the unit is in

Display Command Values mode. Only wire

speed command will be displayed while

welding if the unit is set in Display Command

Values mode, even if the Wire Feed

Speed/Amps Display button is pressed.

.Displays show actual or command values

as determined by configuration menu

when using a PDA with File Management/

WaveWriter software. Command values

are displayed prior to welding and actual

values are displayed while welding unless

a PDA with File Management software

was used to set the unit in the ”Display

Command Values” mode. In the Display

Command Values mode, command

values are displayed while welding.

.If a PDA with File Management/WaveWriter

software is used to change wire feed units

(IPM, MPM) or display welding information

(command or actual),save the changes and

then turn the power to the unit off and then

on again for the changes to be carried out

by the unit.

14 Volts And Arc Adjust LED’s

The lit LED indicates whether voltage or arc

length is being displayed.

15 Upper Display

The upper display shows different information

depending on the active function of the unit

and the weld process being used. When the

display shows voltage (for a MIG process),

the Volts LED lights. When it shows arc adjust

[for a pulsed and RMD (optional) weld

process], the Arc Adjust LED lights. However,

during any weld process (MIG and pulse), the

unit will display actual arc voltage unless a

PDA with File Management/WaveWriter

software has set the unit in the ”Display

Command Values” mode.

Table 4-1. Welding Wire And Gas Abbreviations*

Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation

Steel STL E70, E100, E120 100% CO2,

90% Argon/10% CO2,

85% Argon/15% CO2,

75% Argon/25% CO2,

95% Argon/5% CO2,

95% Argon /5% O2,

98% Argon/2% O2

CO2

C10

C15

C25

C5

OX5

OX2

Stainless Steel SS 308, 309, 312, 316 98% Argon, 2% O2

(81Ar/18HE/1CO2

Accu-pulse)

90HE/7-1/2Ar/2-1/2CO2

MIG/RMD/Accu-pulse)

OX2

Tri Gas

Tri Gas

Cored Tubular Wire MCOR 71, 76, 86R, 409,

439

90% Argon/10% CO2C10

439

98% Argon/2% O2OX2

Aluminum ALUM 4XXX, 5XXX 100% Argon ARGN

* Not all wire types may be available with your unit.

OM-201 540 Page 26

Table 4-2. Robot Abbreviations

Manufacturer Robot Abbreviation

ABB ABB

Fanuc FANU

Daihen DAHN

Kawasaki KAWA

Kuka KUKA

Comau COMU

Hitachi HCHI

Nachi NCHI

Panasonic PANA

Motorman MOTO

Robot Adapter DTEC

Detect Disabled OFF

None Robt DTEC

4-4. Front Panel Switches

Ref. 802 914-A

1 Power Switch

Turns unit On or Off.

The power-up sequence may last up to 30

seconds before the unit is ready to weld.

During power-up, the front panel will display

messages indicating the status of the unit. The

first message is:

NET

WAIT

NET WAIT is an abbreviation for ”network

updating” and means the internal control

network is powering up. The next message is

XXXX (Robot Type)

XXXX identifies the robot adapter being used

as identified by the unit (see Table 4-2 for a list

of robot adapters that could be displayed). To

ensure proper operation of the system, verify

the robot displayed corresponds to the actual

robot being used. The final message is

AUTO

675

AUTO 675 indicates the software being

loaded.

2 Contactor LED

Contactor LED illuminates when weld output is

energized.

3 Purge Push Button

Press button to purge gas line.

4 Gas LED

Gas LED illuminates when Purge push button

is pressed.

5 Jog Push Button

Press button to jog wire.

6 Wirefeed LED

Wirefeed LED illuminates when wire feeds or

retracts.

7 Retract Push Button

Press button to retract wire. Wirefeed LED

illuminates when Retract push button is

pressed.

Auto-Threading feature is activated by

pressing the Jog and Retract buttons

simultaneously. Pressing the Jog, Purge, or

trigger switch will turn off the Auto-Threading

feature.

8 PDA Port

9 PC Port

1

2

3

4

5

6

7

8

9

OM-201 540 Page 27

4-5. Robot Calibration Mode

198 993

Use the robot calibration mode to

custom-calibrate the power source to

the robot command signals. This

ensures the wire speed, voltage, and

arc adjust are the same on the robot

pendant as on the power source.

.The factory recommendation is to

perform the calibration on all

installations or code updates.

Follow this procedure if the factory

settings are not as accurate as

desired. Synchronization of the robot

and power source signals makes

installation easier and improves the

operation of the system.

.The robot pendant must have

Weld enabled, and there can be

no start/stop crater conditions set

in the robot.

The calibration mode will execute as a

”dry run” from the operator’s

perspective. The welding power

source provides the robot with

feedback so the robot thinks a weld is

underway, yet the robot torch need not

move during the calibration.

.If you wish to stop the calibration

procedure, turn unit input power

off and then on again.

If the calibration is performed correctly

the ROBT CAL message stops being

displayed; however, if it is performed

incorrectly, the message remains on

the display.

To start the calibration procedure over

again, turn unit input power off and

then on again following the calibration

setup steps following the calibration

setup steps.

Turn unit On. Unit displays abbreviated name of robot

detected where XXXX appears (see Table 4-2 for a list

of robot adapters that could be displayed).

To enter calibration mode while robot name appears on front panel,

press and hold wire feed/amps button until “ROBT CAL” appears on

front panel. “ROBT CAL” message will not display until after the

power-up sequence is completed (approximately 20 seconds).

Use robot pendant or other method to enter two weld schedules into the

robot. Maintain schedule 1 for at least 10 to 20 seconds minimum before

moving on to schedule 2. Maintain schedule 2 for 10 to 20 seconds

before ending the simulated weld. Schedule data is shown below:

Schedule 1

10.0 Volts

100 IPM

Schedule 2

44.0 Volts

1000 IPM

When the robot calibration mode ends, the ROBT CAL message

stops and the unit will display normal front panel information.

CIRCULER

XXXX

OM-201 540 Page 28

4-6. Robot Auto-Calibration Sample Programs

.It is critical to make certain that NO start power, start conditions, run-in, or crater parameters of any kind are present in the robot program. The

welding power source is looking for 2 distinct welding conditions. If there is a “start power” condition, the welding power source will equate this

as the first condition and fail to execute Auto-Cal correctly. If there is a “crater fill” condition, the welding power source will equate this as the second

condition and fail to execute Auto-Cal correctly.

Actual Motoman Welder Condition File

<Welding Current Output Char.>

NO. REF (V) MEASURE (A)

01 0.01 1

02 7.00 500

03 13.99 999

04 0.00 000

<Welding Voltage Output Char.>

NO. REF (V) MEASURE (V)

01 0.14 0.5

02 7.00 25.0

03 14.00 50.0

04

Sample Auto-Calibration Routine For Motoman Robot

0000 NOP

0001 Mov J

0002 AWELD 1.40 (AWELD direct input of 1.40Volts = 100 ipm)

0003 VWELD 2.80 (VWELD direct input of 2.80Volts = 10.0 volts)

0004 Arcon

0005 Timer T=10.00

0006 Arcof

0007 AWELD 14.00 (AWELD direct input of 14.00Volts = 1000 ipm)

0008 VWELD 12.32 (VWELD direct input of 12.32Volts = 44.0 volts)

0009 Arcon

0010 Timer T=10.00

0011 Arcof

0012 End

OM-201 540 Page 29

Sample Auto-Calibration Routine For Fanuc Robot

1: Call Safehome

2: J P[1] 40% Fine

Arcstart [10.0Volts, 100.0IPM]

3: L P[2] 10.0 sec Fine

Arc End [0.0Volts, 0.0IPM, 0.0Sec]

4: Wait 1.00 (Sec)

5: J P[3] 40% Fine

Arcstart [44.0Volts, 1000.0IPM]

6: L P[4] 10.0 sec Fine

Arc End [0.0Volts, 0.0IPM, 0.0Sec]

7: Call Safehome

Sample Auto-Calibration Routine For ABB Robot

Move J home, v500, z50, tweldgun;

Arcl \ on, *, v500, sm1, wd1, wv0, z50, tweldgun;

Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;

WaitTime 5;

Arcl \ on, *, v500, sm1, wd2, wv0, z50, tweldgun;

Arcl \ off, *, v500, sm1, wd2, wv0, z50, tweldgun;

Move J home, v500, z50, tweldgun;

*Seam Data values must all be set at zero.

Weld Data 1: Weld Data 2:

weld_sched:=0 weld_sched:=0

weld_speed:=5 weld_speed:=5

weld_voltage:=10 weld_voltage:=44

weld_wfs:=100 weld_wfs:=1000

org_weldspeed:=0 org_weldspeed:=0

org_weldvoltage:=0 org_weldvoltage:=0

org_weldwfeed:=0 org_weldwfeed:=0

OM-201 540 Page 30

4-7. Reset Mode

198 993 / 803 246-B

.Reset mode is not active 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.

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

NO

Rotate Adjust knob to change NO

to YES.

Program 1 Pulse

.035 Mild Steel

90% Argon, 10% CO2

Program 2 MIG

.035 Mild Steel

75% Argon, 25% CO2

Program 3 Accu-pulse

.035 Mild Steel

90% Argon, 10% O2

Program 4 Pulse

.045 Mild Steel

90% Argon, 10% CO2

Program 5 MIG

.045 Mild Steel

75% Argon, 25% CO2

Program 6 Accu-pulse

.045 Mild Steel

90% Argon, 10% O2

Program 7 Pulse

.052 Mild Steel

90% Argon, 10% CO2

Program 8 MIG

.052 Mild Steel

75% Argon, 25% CO2

RST

YES

RST

YES

CYCL

PWR

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:

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

OM-201 540 Page 31

SECTION 5 − MAINTENANCE

5-1. Routine Maintenance

!Disconnect power

before maintaining. .Maintain more often

during severe conditions.

n = Check Z = Change ~ = Clean l = Replace

* To be done by Factory Authorized Service Agent Reference

Every

Every

3

Months

l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose nl Weld Cables

3

Months

nl Cords nl Gun Cables

Every

6

Months OR

~ Drive Rolls ~ Inside Unit

5-2. Blowing Out Inside Of Unit

!Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow

through front and back louvers as

shown.

Ref. 802 913-B

OM-201 540 Page 32

SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING

Protect yourself and others from injury — read and follow these precautions.

6-1. Symbol Usage

OM-201 540K - 2007−10, safety_stm 2007−04

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

.Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

6-2. Servicing Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard.

Only qualified persons should test, maintain, and repair this

unit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

DDo not touch live electrical parts.

DTurn Off welding power source and wire feeder

and disconnect and lockout input power using

line disconnect switch, circuit breakers, or by removing plug from re-

ceptacle, or stop engine before servicing unless the procedure spe-

cifically requires an energized unit.

DInsulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

DDo not leave live unit unattended.

DIf this procedure requires an energized unit, have only personnel

familiar with and following standard safety practices do the job.

DWhen testing a live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

DDisconnect input power conductors from deenergized supply line

BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

DTurn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Troubleshooting Section be-

fore touching any parts.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

DUse proper static-proof bags and boxes to

store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

DDo not place unit on, over, or near combustible

surfaces.

DDo not service unit near flammables.

FLYING METAL or DIRT can injure eyes.

DWear safety glasses with side shields or face

shield during servicing.

DBe careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllow cooling period before working on

equipment.

DTo handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

EXPLODING PARTS can cause injury.

DFailed parts can explode or cause other parts to

explode when power is applied to inverters.

DAlways wear a face shield and long sleeves

when servicing inverters.

SHOCK HAZARD from testing.

DTurn Off welding power source and wire feeder

or stop engine before making or changing me-

ter lead connections.

DUse at least one meter lead that has a self-

retaining spring clip such as an alligator clip.

DRead instructions for test equipment.

OM-201 540 Page 33

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

DUse equipment of adequate capacity to lift and

support unit.

DIf using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

MOVING PARTS can cause injury.

DKeep away from moving parts such as fans.

DKeep away from pinch points such as drive

rolls.

DHave only qualified persons remove doors,

panels, covers, or guards for maintenance as

necessary.

DKeep hands, hair, loose clothing, and tools

away from moving parts.

DReinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

DWearers of Pacemakers and other Implanted

Medical Devices should keep away from serv-

icing areas until consulting their doctor and the

device manufacturer.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before

starting to weld again.

DDo not block or filter airflow to unit.

H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

DHave only qualified persons familiar with

electronic equipment install, test, and service

H.F. producing units.

DThe user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

DIf notified by the FCC about interference, stop using the

equipment at once.

DHave the installation regularly checked and maintained.

DKeep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

READ INSTRUCTIONS.

DUse Testing Booklet (Part No. 150 853) when

servicing this unit.

DConsult the Owner’s Manual for welding safety

precautions.

DUse only genuine replacement parts from the

manufacturer.

6-3. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

6-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

OM-201 540 Page 34

SECTION 7 − TROUBLESHOOTING

7-1. Set Value Mode

Program

Process

Wire Type

Gas Type

Adjust

Volts Arc Adjust

Wire Speed Amps

Setup Arc Control

Wirefeed

Gas

Contactor

The Set Value mode is a troubleshooting tool

that allows certain robot command values to

be manually over-ridden.

1 Setup Push Button

2 Arc Control Push Button

3 Adjust Knob

4 Wire Feed Speed/Amps Display Push

Button

Enter the Set Value mode by pressing the

Setup and Arc Control push buttons at the

same time. When in the Set Value mode the

display windows briefly shows SET VALU and

the blinking LED’s under the display windows

indicate whether Volts, Arc Adjust, or Wire

Speed can be changed turning the Adjust

knob.

Depending on the defined weld process,

either volts (MIG) or arc adjust [pulse,

Accu-pulse, or RMD (optional)] can be

changed in the top display. Wire speed can be

changed in the bottom display. Press the Wire

Feed Speed/Amps push button to toggle

between selecting information in the top

display or bottom display. The LED under the

active display will blink to indicate the value

that can be changed.

Rotate the Adjust knob to change values.

Exit the Set Value mode by pressing the Setup

and Arc Control push buttons at the same time

or turning power source off and then back on

again.

12

3

4

OM-201 540 Page 35

7-2. Diagnostics

ERR TACH

•Tach error for Tach A 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.

•Tach error for Tach B 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

•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

•The wire feed speed error indicates actual

wire feed speed does not match wire feed

speed command. Press Jog/Purge button

to clear error.

ERR STRT

•The start error, when enabled, occurs if the

trigger is held longer than three seconds

without an arc start. The error may be

cleared by releasing the trigger, and

pressing the Jog/Purge button.

ERR STOP

•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

•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

•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

•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. Turn

power off and back on to clear error.

ERR STUK

•The stuck error occurs if the welding wire

sticks to the workpiece at the end of a weld.

May be caused by poor weld conditions.

The error may be cleared by cutting wire

from workpiece, and pressing the Jog/

Purge button.

ERR TEMP

•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. If problem persists,

check fan motors and thermistors for proper

operation. If unit is not overheated, check in-

put line voltage. If input line voltage is okay,

contact nearest factory authorized Service

Agent.

ERR LINE

•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

•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.

The following error messages are shown on the

upper and lower displays to indicate specific errors.

Explanations are in the text below:

ERR

TACH

ERR

MOTR

ERR

WFS

ERR

STRT

ERR

STOP

Indicates a

tachometer error. Indicates a motor

error. Indicates a wire

feed speed error. Indicates an arc

start error. Indicates an arc

stop error.

ERR

FLOW

ERR

COOL

ERR

GND

ERR

STUK

Indicates a gas

flow error.

Indicates a coolant

flow error. Indicates a ground

current error. Indicates a wire

stuck error.

ERR

TEMP

ERR

LINE

ERR

ARC

Indicates a

temperature error. Indicates a line

error. Indicates an arc

error.

OM-201 540 Page 36

7-2. Diagnostics (Continued)

WELD WAIT

•The weld wait error indicates unit was not

ready for a weld sequence. Press Jog/

Purge button to clear error.

MOTR COM

•The motor communication error indi-

cates motor board lost data communica-

tions. Press Jog/Purge button to clear error.

If condition persists, contact nearest factory

authorized service agent.

PLS WAIT

•The uim communication error indicates

user interface board lost data

communications. Press Jog/Purge button

to clear error. If condition persists, contact

nearest factory authorized service agent.

LOW WFS

•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

•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. Only applies

to units equipped with E stop option.

RMD DONE

•The RMD done message indicates the

RMD demo is completed. Pressing

Jog/Purge button will change the screen to

CYCL PWR on the display. Turn unit power

off and back on again.

OVER AVG

•The over average error indicates that

current is outside the average range for the

set program parameters. Check and correct

program parameters. Press Jog/Purge

button to clear error.

REL TRIG

•The release trigger error indicates the

user held the gun trigger after an E stop was

reset causing the contactor to remain on.

Press Jog/Purge button to clear error.

TRIG STUK

•The trigger stuck error indicates the user

held the gun trigger during power up.

Release trigger and turn power off and back

on.

ERR UNKN

•The unknown error indicates an error was

sent from the PCM board to the UIM, but

error condition is unknown. Make sure

welding power source is isolated from the

welding fixture. Press Jog/Purge button to

clear error.

OVER CRNT

•The over current error indicates welding

power source primary current of the inverter

is too high. Turn welding power source off

and disconnect unit for servicing.

Attempting to reset the display to

continue welding may further damage

internal components. A complete

prepower check of the unit is needed

including resistance measurements of R1

and R8 resistors on welding power source

Interconnect board. Resistors should

measure 30K ohms. Visually inspect

electrolytic capacitors C1 and C2 for any

possible damage. In the event of an over

voltage condition, R1 and R8 could open

potentially causing an imbalance in the

power circuit. This condition would create

excessive current in the inverter primary

transformer and result in the OVER CRNT

error.

WELD

WAIT

MOTR

COM

PLS

WAIT

Indicates a weld

cycle wait error. Indicates a motor

communication error. Indicates a UIM

communication error.

LOW

Indicates a low WFS

command error.

WFS

E

STOP

RMD

DONE

OVER

AVG

Indicates an

emergency stop error. Indicates RMD

demo is done.

Indicates an over

average current error.

OVER

CRNT

Indicates an

overcurrent error.

REL

TRIG

ERR

UNKN

Indicates a contactor

on error. Indicates an

unknown error.

TRIG

STUK

Indicates a trigger

closed error.

OM-201 540 Page 37

7-3. Removing Cover and Measuring Input Capacitor Voltage

Turn Off welding power source, and

disconnect input power.

Remove cover

1 Power Interconnect Board

PC2

2 Voltmeter

Measure the dc voltage across the

+ bus terminal and − bus terminal on

PC2 as shown until voltage drops to

near 0 (zero) volts. Measure input

capacitor voltage on all three

inverter assemblies before

proceeding.

3 Typical Bleeder Resistor

An example of a typical bleeder

resistor is shown on this page.

Proceed with job inside unit.

Reinstall cover when finished.

Tools Needed:

5/16 in

802 301-B / Ref. 803 001-A

!900 Volts dc can be present on the capacitor bus and

significant DC voltage can remain on capacitors

after unit is Off. Always check the voltage on both

inverter assemblies as shown to be sure the input

capacitors have discharged before working on unit.

1

2

+ lead to left bus terminal, − lead to right

bus terminal

1

2

1

2

+ lead to left bus terminal, − lead to right

bus terminal

+ lead to left bus terminal, − lead to right

bus terminal

3

Typical Bleeder Resistor

#16 AWG 1000 volts dc

insulation rating, approx

3 in (76 mm) leads

25 to 1000 ohm, 5

watt resistor

OM-201 540 Page 38

1 Process Control Module PC4

Diagnostic LED’s are visible inside unit,

located on PC4 mounted on the top tray.

Refer to Section 7-5 for information on

diagnostic LED’s.

Reinstall cover after checking diagnostic

LED’s.

216 956-A / Ref. 803 001-B

7-4. Process Control Module PC4 Diagnostic LED’s

1

LED2

LED1

LED4

LED3

7-5. Diagnostic LED’s On Process Control Module PC4

LED Status Diagnosis

1 On Indicates −25 volts dc is present on process control module PC4

Off Indicates −25 volts dc is not present on process control module PC4

2 On Indicates +25 volts dc is present on process control module PC4

Off Indicates +25 volts dc is not present on process control module PC4

3,4 On See Network Status Table in Section 7-12

Off See Network Status Table in Section 7-12

OM-201 540 Page 39

1 Wire Feed Module PC6

Diagnostic LED’s are visible inside

unit, located on PC6 mounted on

the top tray assembly.

Refer to Section 7-7 for information

on diagnostic LED’s.

Reinstall top cover after checking

diagnostic LED’s.

2 Dip Switch S1

Dip switches are used to identify

each circuit board on the internal

network. Dip switch settings are

different for each circuit board. For

proper operation, do not change dip

settings from those shown.

7-6. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings

217 333-B / 803 300-A

2

1LED1 LED2

LED3

LED4

7-7. Diagnostic LED’s On Wire Feed Module PC6

LED Status Diagnosis

1 On Indicates +15 volts dc is present on wire feed module PC6

Off Indicates +15 volts dc is not present on wire feed module PC6

2 On Indicates +5 volts dc is present on wire feed module PC6

Off Indicates +5 volts dc is not present on wire feed module PC6

3,4 On See Network Status Table in Section 7-12

Off See Network Status Table in Section 7-12

OM-201 540 Page 40

1 User Interface Module PC7

Diagnostic LED’s are visible inside unit,

located on PC7 mounted behind the front

panel.

Refer to Section 7-9 for information on

diagnostic LED’s.

Reinstall cover after checking diagnostic

LED’s.

2 Dip Switch S1

3 Dip Switch S2

Dip switches are used to identify each

circuit board on the internal network. Dip

switch settings are different for each circuit

board. For proper operation, do not change

dip settings from those shown.

218 559-A / 803 300-A

7-8. User Interface Module PC7 Diagnostic LED’s

2

3

1

LED1

LED2

7-9. Diagnostic LED’s On User Interface Module PC7

LED Status Diagnosis

1, 2 On See Network Status Table in Section 7-12

Off See Network Status Table in Section 7-12

OM-201 540 Page 41

1 Automation Interface Module PC9

Diagnostic LED’s are visible inside unit,

located on PC9 mounted on left side.

Refer to Section 7-11 for information on

diagnostic LED’s.

Reinstall cover after checking diagnostic

LED’s.

2 Dip Switch S4

Dip switches are used to identify each

circuit board on the internal network. Dip

switch settings are different for each circuit

board. For proper operation, do not change

dip settings from those shown.

216 958-A / Ref. 803 301-B

7-10. Automation Interface Module PC9 Diagnostic LED’s

2

LED32

LED33

LED30

LED31

1

LED1

LED20

LED15

LED2

LED3

LED4

LED5

LED6

LED7

LED8

LED9

LED10

LED11

LED12

LED13

LED14

LED19 LED18

LED17

LED16 LED21 LED22 LED23 LED24 LED26 LED29

LED25

LED27

LED28

OM-201 540 Page 42

7-11. Diagnostic LED’s On Automation Interface Module PC9

LED Status Diagnosis

1 On Input signal On from robot for jog advance

Off Input signal Off from robot for no jog advance

2 On Input signal On from robot to energize contactor

Off Input signal Off from robot to not energize contactor

3 On Input signal On remote program A selected

Off Input signal Off remote program A not selected

4 On Input signal On remote program C selected

Off Input signal Off remote program C not selected

5 On Input signal On from E-stop board PC12 for no emergency stop

Off Input signal Off from E-stop board PC12 acknowledges E-stop is On from robot

6 On Spare 1 not assigned

Off Spare 1 not assigned

7 On Input signal On Autoset-C selected

Off Input signal Off Autoset-C not selected

8 On Input signal On Autoset-B selected

Off Input signal Off Autoset-B not selected

9 On Input signal On Remote Jog on from peripheral plug

Off Input signal Off Remote Jog off from peripheral plug

10 On Input signal On Remote Purge on from peripheral plug

Off Input signal Off Remote Purge off from peripheral plug

11 On Input signal On from robot for jog retract

Off Input signal Off from robot for no jog retract

12 On Input signal On from robot for purge

Off Input signal Off from robot for no purge

13 On Input signal On remote program B selected

Off Input signal Off remote program B not selected

14 On Input signal On Touch Sensor on from robot or peripheral plug

Off Input signal Off Touch Sensor off from robot or peripheral plug

15 On Spare 0 not assigned

Off Spare 0 not assigned

16 On Spare 2 not assigned

Off Spare 2 not assigned

17 On Input signal On Autoset-A selected

Off Input signal Off Autoset-A not selected

18 On Input signal On Autoset-D selected

Off Input signal Off Autoset-D not selected

19 On Input signal On Remote Retract on from peripheral plug

Off Input signal Off Remote Retract off from peripheral plug

20 On Input signal On Remote Water Flow on from peripheral plug

Off Input signal Off Remote Water Flow off from peripheral plug

21 On Input signal On from robot for no emergency stop

Off Input signal Off from robot for emergency stop

23 On Input signal On from relay K3 for welding power source ready and no detected errors present

Off Input signal Off from relay K3 for welding power source not ready, detected errors are present, or unit is

in operating mode preventing the weld ready signal from being enabled

OM-201 540 Page 43

LED DiagnosisStatus

24 On Input signal On from relay K4 to indicated wire stuck in weld joint

Off Input signal Off from relay K4 to indicate wire is not stuck in weld joint

25 On Indicates +5 volts dc is present on automation interface module PC9

Off Indicates +5 volts dc is not present on automation interface module PC9

26 On Input signal on from relay K5 for flow (shielding gas or coolant) present

Off Input signal off from relay K5 for flow (shielding gas or coolant) not present

27 On Indicates −15 volts dc is present on automation interface module PC9

Off Indicates −15 volts dc is not present on automation interface module PC9

28 On Indicates +15 volts dc is present on automation interface module PC9

Off Indicates +15 volts dc is not present on automation interface module PC9

29 On Input signal on from relay K6 for arc detected

Off Input signal off from relay K6 for no arc detected

30, 31 On See Network Status Table in Section 7-12

Off See Network Status Table in Section 7-12

32 On Input signal on for aux. relay energized

Off Input signal off for aux. relay energized

33 On Input signal on touch sensor touch detected

Off Input signal off touch sensor touch not detected

OM-201 540 Page 44

7-12. Network And Module Status LED’s

A. Network Status LED’s

The following are network status LED’s:

LED1 on the UIM circuit board

LED4 on the WFM and PCM circuit boards

LED30 on the AIM circuit board.

Status Diagnosis

Off The circuit board is not on-line with the network or there is no power applied to the circuit board.

Green The circuit board is operating normally and the on-line connection is made with the network.

Flashing Green The circuit board is wait for an on-line connection to be made with the network.

Red The circuit board has encountered a communication link failure with the network. Check DeviceNet cable connections. Verify

dip switch positions according to Sections 1-2 and 1-3. Replace circuit board if necessary.

B. Module Status LED’s

The following are module status LED’s:

LED2 on the UIM circuit board

LED3 on the WFM and PCM circuit boards

LED31 on the AIM circuit board.

Status Diagnosis

Off There is no power applied to the circuit board or the board software is not executing its functions.

Green The circuit board is operating normally.

Flashing Red The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.

Red The circuit board has encountered an unrecoverable fault.

OM-201 540 Page 45

7-13. Troubleshooting

Trouble Remedy

No weld output; completely inoperative Place line disconnect in On position (see Section 3-13).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-13).

Check for proper input power connections (see Section 3-13).

No weld output; meter display on with no

error displayed. Check to see if the contactor indicator light is lit when contactor line is asserted on.

Erratic or improper weld output with no

errors displayed.

Use proper size and type of weld cable (see Section 3-9).

errors displayed.

Check that proper program for wire size, process, and shielding gas is loaded.

Clean and tighten all weld connections.

No 115 volts AC at the duplex receptacle. Reset supplementary protector CB1 (see Section 3-7).

Wire does not feed. Check supplementary protector CB2 and reset if necessary (see Section 3-7).

Check motor control cable connections.

Wire feeds erratically. Readjust hub tension.

Readjust drive roll pressure.

Clean or replace dirty or worn drive rolls.

Remove weld spatter around the nozzle opening.

Replace contact tip or liner. See gun Owner’s Manual.

Check motor control cable connections.

Wire feeds as soon as power is supplied. Check gun trigger. See gun Owner’s Manual.

Wire stubbing on low end using a

constant current power source.

Increase output setting of the power source.

constant current power source.

Check voltage sense lead connection, clean and tighten if necessary.

Gas does not flow or does not stop flow-

ing; wire feeds. Check gas valve and flow meter.

Wire burns back to gun contact tip when

using electrode negative (straight

polarity) process.

Check to be sure that volt sense lead is connected to the work.

OM-201 540 Page 46

SECTION 8 − ELECTRICAL DIAGRAMS

Figure 6-1. Circuit Diagram For Welding Power Source (1 Of 2)

OM-201 540 Page 47

198 992-G (Part 1 Of 2)

OM-201 540 Page 48

Figure 6-2. Circuit Diagram For Welding Power Source (2 Of 2)

OM-201 540 Page 49

198 992-G (Part 2 Of 2)

OM-201 540 Page 50

Figure 6-3. Circuit Diagram For 72 Pin Robot Interface

OM-201 540 Page 51

219 266-C

OM-201 540 Page 52

Figure 6-4. Circuit Diagram For Peripheral/Motor Interface

OM-201 540 Page 53

219 267-B

OM-201 540 Page 54

SECTION 9 − PARTS LIST

.Hardware is common and

not available unless listed.

Ref. 802 919-C

8

8

3

1

2

11

15

13

14

12

9

15

10

6

5

5

6

4 − Fig 9-3

5 − Fig 9-2

7 − Fig 9-4

16 − Fig 9-5

15

17

19

18

18

Figure 9-1. Main Assembly

OM-201 540 Page 55

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 9-1. Main Assembly

Quanti

ty

1 T2 212543 Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 210492 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 210481 Plate, Mtg Toroid Xfmr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Fig 9-3 Top Tray Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 IM1,IM2,IM3 214597 Windtunnel, LH w/Components (Fig 9-2) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222958 Windtunnel, RH w/Components (Fig 9-2) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 198961 Panel, Module Divider 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Fig 9-4 Rear Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 227791 Panel, Side W/Insulator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 210482 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 W1 160793 Contactor, DEF PRP 60A 3P 24VAC Coil W/Boxlug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 213386 Assembly, Filter (Primary) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 HD2 182918 Transducer, Current 400A Module Supply V +/− 15V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 198951 Block, Terminal 3 Pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 148025 Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 218356 Filter Assy, Secondary 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 Fig 9-5 Front Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

227855 Kit, Connectors W/Washer For Power Cables (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 010467 Connector, Clamp Cable 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 225840 Washer, Reducer 1.25 in − 0.75 in 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 010916 Connector, Clamp Cable 0.750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

802 955-A

3

4

5678

33 34 35 17 18

20 21 23 24

25

23

36

29

26

13

27

28

30

31

10

11

15

14

2

9

19

37

38

23

22

32

12

.Hardware is common and

not available unless listed.

7

6

13

1

16

Figure 9-2. Windtunnel Assembly LH And RH

OM-201 540 Page 56

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 9-2. Windtunnel Assembly LH And RH (Fig 9-1 Item 6)

Quanti

ty

1 214597 Windtunnel, LH w/Components (including). 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 196351 Windtunnel, LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 L1 213940 Inductor, Input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 214519 Insulator, Heat Sink Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R3, C4 233052 Resistor/Capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 199840 Bus Bar, Diode 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 D1, D2 201531 Kit, Diode Power Module 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 196347 Heat Sink, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 196349 Spacer, Windtunnel 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 T1 203408 Xfmr, HF Litz/Litz 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Z1 220496 Output Inductor Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 170647 Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 179276 Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 196355 Insulator, Screw 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 010546 Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 222958 Windtunnel, RH w/Components (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 196332 Windtunnel, RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 030170 Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 196259 Plugs, w/Leads & Current Xfmr (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115092 Housing, Plug & Skts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115091 Housing, Plug & Skts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT1 196231 Xfmr, Current Sensing 200/1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 201695 Clamp, Capacitor (Bottom) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 C1, C2 226081 Capacitor,Elctlt 2400 Uf 500 Vdc Can 2.50 Dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 210507 Clamp, Capacitor (Top) Machined 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 217625 Kit, Input/Pre−regulator And Inverter Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 RT1, RT2 214015 Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead 1. . . . . . . . . . . . . . . . . . . . . . . . .

25 PC2 222661 Circuit Card Assy, Power Interconnect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 C3 196143 Capacitor, Polyp Met Film 16. Uf 400 VAC 10% 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 196378 Bracket, Mtg Current Xfmr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 HD1 182918 Transducer, Current 400A Module Supply V +/− 15v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196384 Cable, Transducer 20in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 R1, R2 196343 Resistors, W/Leads & Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196840 Insulator, Resistors/Interface Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 109056 Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 196514 Gasket, Inductor Mounting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 196512 Bracket, Inductor Mounting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 196330 Heat Sink, Power Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 L2 196345 Coil, Inductor (Pre−regulator) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 196588 Baffle, Foam Rubber (Lower) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196365 Plugs, w/Leads (Fan) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199136 Plugs, w/Leads (PC2 To PC1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 PC1 214523 Circuit Card Assy, Control (Inverter 300A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 204846 Insulator, Screw 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 083147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-201 540 Page 57

.Hardware is common and

not available unless listed.

802 916-B

1

2

3

4

56

7

8

9

10

11

Figure 9-3. Top Tray Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 9-3. Top Tray Assembly (Fig 9-1 Item 4)

Quanti

ty

1 PC12 209676 Circuit Card Assy, E−stop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 PC3 231928 Circuit Card Assy, Aux Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 210490 Bracket, Mtg PC Card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134201 Stand−Off, PC Card .312/.375/Post&Lock .43 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 083147 Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 PC4 221277 Process Control Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 170647 Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 210491 Tray, Mtg PC Card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 223439 Insulator, Circuit Card (Aux Power) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 198122 Stand−Off Support, PC Card .250 w/Post&Lock .500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 PC6 221280 Wire Feed Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-201 540 Page 58

.Hardware is common and

not available unless listed.

802 917-B

11

9

67

14 12

10

8

5

4

3

2

1

13

15

Figure 9-4. Rear Panel Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 9-4. Rear Panel Assembly

Quanti

ty

1 PC9 221279 Automation Interface Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 199297 Stand-off, no 6-32 & no 8-32 x 2.50 lg .312 hex alm/m 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 PC10 214855 Circuit Card Assy, Robot Interface Filter HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 199295 Stand-off, no 8-32 x .500 lg .312 hex al m&f 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 217297 Cover, Receptacle Weatherproof Duplex Rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 210471 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 210358 Bolt, eye shld thd stem .500−13 X 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 210 505 Nameplate, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 201058 Connector, Rect 72 Pin Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 210483 Bracket, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CB1 083432 Supplementary Protector, Man Reset 1P 10A 250VAC Frict 1. . . . . . . . . . . . . . . . . . . . . . . . .

12 CB2 093995 Supplementary Protector, Man Reset 1P 15A 250VAC Frict 1. . . . . . . . . . . . . . . . . . . . . . . . .

13 PC11 216213 Circuit Card Assy, Motor Filter HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 RC2 604176 Receptacle, w/Leads (115V Duplex) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 216596 Strap, Grounding 4.50 in long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-201 540 Page 59

.Hardware is common and

not available unless listed.

Ref. 802 918-B

1

2

3

5

7

6

4

27

26

25

9

18

17

16

8

19

23

22

21

21

20

12

13

10

11

10

12

24

15

14

Figure 9-5. Front Panel Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 9-5. Front Panel Assembly

Quanti

ty

1 S1 207456 Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg 1. . . . . . . . . . . . . . . . . . . . . . . .

2 207895 Insulator,Switch Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 179851 Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 204393 Panel, PC Card Front (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204394 Panel, PC Card Switch/Overlay (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 200410 Nameplate, Overlay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 PC20 227879 Circuit Card Assy, Switches 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC7 221278 User Interface Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200416 Circuit Card Assy, Display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199376 Circuit Card Assy, User Interface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 FM 196313 Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC13 208071 Circuit Card Assy,ISO/COMM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 C6, C7, C8 206878 Capacitor Assy 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 213102 Choke, Common Mode w/Leads 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 025248 Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-201 540 Page 60

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 9-5. Front Panel Assembly (Continued)

Quanti

ty

13 220815 Bus Bar, Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 210864 Bus Bar, Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 210866 Terminal, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RC5 214664 Receptacle, Common Mode Choke 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 216966 Cover, Connector D-sub 9 pin Male w/Chain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 216965 Cover, Connector D-sub 9 skt Female w/Chain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 219843 Label, Volt Sense 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 207896 Box, Louver 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 186621 Boot, Generic 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 PB1, PB2, PB3 199443 Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt 3. . . . . . . . . . . . . . . . . . .

23 212780 Nameplate, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 210865 Terminal, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 210469 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 210483 Bracket, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 210358 Bolt, eye shld thd stem .500−13 X 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

Notes

Warranty Questions?

Call

1-800-4-A-MILLER

for your local

Miller distributor.

miller_warr 2007−01

Your distributor also gives

you ...

Service

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Support

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY − Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to

its original retail purchaser that new Miller equipment sold after

the effective date of this limited warranty is free of defects in

material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to

an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Process Controllers

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

* Water Coolant Systems (Non-Integrated)

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Spot Welders

* Load Banks

* Arc Stud Power Sources & Arc Stud Guns

* Racks

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

* Bernard-Branded Mig Guns (No Labor)

* Weldcraft-Branded TIG Torches (No Labor)

* Subarc Wire Drive Assemblies

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 & SAF Model Plasma Cutting Torches

* Remote Controls

* Accessory (Kits)

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays

or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase 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 allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

but may vary from province to province.

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & 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

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

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

Contact the Delivering Carrier to:

For Service

Owner’s Record

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims, contact

your distributor and/or equipment manufacturer’s

Transportation Department.

Contact your Distributor for:

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller