Miller Continuum Owner's Manual

Download

Page 1

OM-266409D 2016−11 Processes

Processes

MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) W elding

Description

Wire Feeder

Continuum

Dual Wire Feeder

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

File: Advanced Manufacturing Systems

Page 2

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

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

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard.

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.

Working as hard as you do

− every power source from Miller is backed by the most hassle-free warranty in the business.

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.

Mil_Thank 2009−09

Page 3

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 8.........................................................

2-6. Informations relatives aux CEM 8.........................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Additional Safety Symbols And Definitions 9................................................

3-2. Miscellaneous Symbols And Definitions 11..................................................

SECTION 4 − SPECIFICATIONS 12..............................................................

4-1. Serial Number And Rating Label Location 12................................................

4-2. Specifications 12........................................................................

4-3. Environmental Specifications 12...........................................................

4-4. Wire Type, Size, And Wire Feed Speed Table 12.............................................

SECTION 5 − INSTALLATION 13................................................................

5-1. Power Source And Wire Feeder Site Selection 13............................................

5-2. Feeder Location 14......................................................................

5-3. Mounting Hole Location 14...............................................................

5-4. Connection Diagram 15..................................................................

5-5. Connecting Weld Output Cable 16.........................................................

5-6. Remote 10 Wire Feeder Control Receptacle RC2 Information 17................................

5-7. Control Cable Connections 18.............................................................

5-8. Wire Feeder Lower Front Panel Connections 18..............................................

5-9. Shielding Gas Hose Connection 19........................................................

5-10. Jog/Retract Switch 19...................................................................

5-11. Rotating Drive Assembly 20..............................................................

5-12. Installing Welding Gun 21................................................................

5-13. Installing Wire Guides And Drive Rolls 22...................................................

5-14. Installing And Threading Welding Wire 23...................................................

5-15. Wire Feeder User Interface 24............................................................

5-16. Description Of Front Panel Controls (See Section 5-15) 25.....................................

5-17. Wire Feeder Lower Panel Controls 26......................................................

5-18. LCD Home Screen 27...................................................................

5-19. Setup Menu 27.........................................................................

5-20. Logs Menu 28..........................................................................

5-21. Status Menu 28.........................................................................

5-22. Creating, Changing And Saving a Weld Program 29..........................................

5-23. Trigger Configuration 29..................................................................

5-24. Weld Sequence Configuration 30..........................................................

5-25. Feedback Configuration 31...............................................................

5-26. System Menu 31........................................................................

Page 4

TABLE OF CONTENTS

5-27. Factory Reset 32.......................................................................

5-28. USB Functions 32.......................................................................

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 33.........................................

6-1. Routine Maintenance 33.................................................................

6-2. Error Code Troubleshooting Description And Tables 34........................................

6-3. Troubleshooting 38......................................................................

SECTION 7 − ELECTRICAL DIAGRAM 40........................................................

SECTION 8 − PARTS LIST 42...................................................................

WARRANTY

Page 5

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

s s

Protect yourself and others from injury — read, follow , and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

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 explained in the text.

NOTICE − Indicates statements not related to personal injury .

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 shock or severe burns. The electrode and work circuit i electrically live whenever the output is on. The inpu power circuit and machine internal circuits are also live when power is on. In semiautomatic or automati wire welding, the wire, wire reel, drive roll housing and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperl grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats

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

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

there is a danger of falling.

D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable 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 voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install, ground, and operate this equipment according to

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

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING P ARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or repaired cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

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

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

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

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed. D Allow cooling period before working on

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-266409 Page 1

Page 6

FUMES AND GASES can be hazardous.

r t

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

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

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

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

D Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

FLYING ME TA L o r DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut o f f compressed gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EM can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implante

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their docto

and the device manufacturer before going near arc welding, spo welding, gouging, plasma arc cutting, or induction heating operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise lev-

el is high.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly of f from the welding arc. The flying sparks, hot

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.

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

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

D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.

D Do not use welder to thaw frozen pipes.

OM-266409 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

Compressed 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 .

D Protect compressed gas cylinders from excessive heat, mechani-

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

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder − explosion will result. D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient n u m -

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

Page 7

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

p g

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

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

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

MOVING PARTS can injure.

D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual c a r efully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

D Use only genuine replacement parts from the manufacturer. D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and local codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts. D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jum

start vehicles unless it has a battery chargin feature designed for this purpose.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

D 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.

OM-266409 Page 3

Page 8

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.)

1-5. Principal Safety Standards

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org o r purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for W elding and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for W elding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and w w w. sparky .org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFP A Standard 51B, from National Fire Protection Association,

Quincy, M A 0 2 2 6 9 ( p h o n e : 1 - 8 0 0 - 3 4 4 - 3 555, website : w w w.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, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

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

2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.

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

4. Keep head and trunk as far away from the equipment in the welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire feeder.

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 recommended.

OM-266409 Page 4

Page 9

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.

2-1 . Symboles utilisés

fre_som_2015−09

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 dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessures personnelles.

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

Les symboles représentés ci-dessous sont utilisés dans ce manuel pour a ttirer l’attention et i dentifier les d angers possibles. E n présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matièr e de sécuri té indiquées c i-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonctionner, 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 m étalliques 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.

D Ne pas toucher aux pièces électriques sous tension. D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’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 cou p e r o u l e s o l .

D Ne pas se servir de source électrique à courant électrique dans les

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

D Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D Si 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.

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

tions suivantes : risques électriques dans un environnement humide o u s i 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 recommandée. En outre, ne pas travailler seul !

. 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.

D Couper 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 normes de sécurité).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.

D Toujours 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.

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

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

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

protégez−les contre les étincelles et les pièces métalliques chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −, le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

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

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

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide doublée.

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

champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. D S’assurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer 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.

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

contact avec tout objet métallique.

D Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.

D Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.

D Arrêter 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.

OM-266409 Page 5

Page 10

LES PIÈCES CHAUDES peuvent

ère

r la

ls ut nt

à s f-

)

provoquer des brûlures.

D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant

de travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leu inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer les fumées. D À 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. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquels est exposé le personnel.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les cons ommables, les p roduit s d e r efroidis s ement, l es dégraisseurs, les flux et les métaux.

D Travailler 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.

D Ne 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 former des gaz hautement toxiques et irritants.

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

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement 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 e t tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuven provoquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage gén

infrarouges) susceptibles de provoquer des brûlures dans les yeux et su peau. Des étincelles sont projetées pendant le soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D Avoir 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.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

des ray ons vis i bles et i nvisibles i ntenses ( ult raviolets

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés te que des réservoirs, tambours ou des conduites pe provoquer leur éclatement. Des étincelles peuve

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

pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un sur-

OM-266409 Page 6

chauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D Déplacer 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.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

D Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déc l e n c h e r u n i n c e n d i e d e l ’ a u t r e c ô t é .

D Ne 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 et AWS A6.0 (voir les Normes de Sécurité).

D Ne pas s ouder l à où l ’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

D Brancher l e c â b l e d e m a s s e 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 provoquant des risques d’électrocution, d’étincelles et d’incendie.

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

lées.

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

électrode o u couper le fil à la pointe de contact.

D Porter un équipement de protection pour le corps fait d’un matériau

D Avant de souder , retirer toute substance combustible de vos po-

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

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

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre 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.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DE SALETES peuvent provoquer de blessures dans les yeux.

D Le soudage, l’écaillement, le passage de l a pièce la brosse en fil de fer, et le meulage génèrent des étincelles et de particules métalliques volantes. Pendant la période de re roidissement des soudures, elles risquent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écra

facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à distance.

D Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.

Page 11

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent explose si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille es

les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

D Protéger 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.

D Placer 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.

endommagée, elle peut exploser. Du fait que

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion. D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D Tourner l e dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

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

D Utiliser les équipements corrects, les bonnes procédures et su ffi-

samment de personnes pour soulever et déplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de l a C GA (Compressed Gas Association) mentionné dans les principales normes de sécurité.

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

Risque D’INCENDIE OU D’EXPLOSION .

D Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de pro-

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

duits inflammables.

LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

D Ne pas obstruer les passages d’air du poste.

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.

D Porter u n écran facial pour protéger le visage et

les yeux.

la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

D Affûter l’électrode au tungstène uniquement à

LES CHARGES ÉLECTROSTATI QUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent causer des blessures.

D Ne pas s’approcher des organes mobiles.

D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.

L’EXPLOSION DE LA BATTERI peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent causer des blessures.

D S’abstenir d e toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.

OM-266409 Page 7

Page 12

LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.

D Le rayonnement haute fréquence (H.F.) peut

pements d e r a d i o−navigation et de communication, les services de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil. D Effectuer régulièrement le contrôle et l’entretien de l’installation. D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.

provoquer des interférences avec les équi-

D Veiller à c e que tout l’équipement de la zone de soudage soit com- D Pour réduire la possibilité d’interférence, maintenir les câbles de

D Veiller à souder à une distance de 100 mètres de tout équipement D Veiller à ce que ce poste de soudage soit posé et mis à la terre D En cas d’interférences après avoir pris les mesures précédentes,

2-4 . Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de provoquer des interférences.

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

patible électromagnétiquement. soudage aussi courts que possible, les grouper, et les poser aussi

bas que possible (ex. par terre). électronique sensible. conformément à ce mode d’emploi. il incombe à l’utilisateur de prendre des mesures supplémentaires

telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’É tat de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants)

2-5. Principales normes de sécurité

Safe Practices for the Preparation of Containers and Piping for W elding and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for W elding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après

utilisation.

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFP A Standard 51B, from National Fire Protection Association,

Quincy, M A 0 2 2 6 9 ( p h o n e : 1 - 8 0 0 - 3 4 4 - 3 555, website : w w w.nfpa.org). OSHA, Occupational Safety and Health Standards for General Indus-

Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ électromagnétique (CEM) autour d u circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: Limiter par exemple tout accès aux passants ou procéder à une évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

OM-266409 Page 8

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

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

4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.

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

6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le dévidoir.

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 chauf fage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.

Page 13

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information.

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe1 2012−05

Safe37 2012−05

Safe2 2012−05

Protect yourself from electric shock by insulating yourself from work and ground.

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Safe3 2012−05

Safe5 2012−05

Safe6 2012−05

Safe8 2012−05

Safe10 2012−05

Keep flammables away from welding. Do not weld near flammables.

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

OM-266409 Page 9

Safe12 2012−05

Safe14 2012−05

Page 14

Do not weld on drums or any closed containers.

Do not remove or paint over (cover) the label.

Disconnect input plug or power before working on machine.

Drive rolls can injure fingers.

Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away .

Safe16 2012−05

Safe20 2012−05

Safe30 2012−05

Safe32 2012−05

Safe33 2012−05

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. W ear complete body protection.

Safe38 2012−05

Become trained and read the instructions before working on the machine or welding.

Safe40 2012−05

OM-266409 Page 10

Page 15

3-2. Miscellaneous Symbols And Definitions

Notes

Some symbols are found only on CE products.

Output

Duty Cycle Wire Feed Percent

Input

Constant Current Circuit Breaker Constant Voltage Slow

Trigger Hold Off Trigger Hold On

Read Instructions

Primary Current Sequence Program Process

Wire Type Gas Type

Arc Length Line Connection USB Memory

Three Phase Arc Control Push Button

Amperes

Cold Jog (Inch)

Towards

Workpiece

Primary Voltage

Volts

Purge By Gas Fast

Rated Welding

Current

Conventional Load

Voltage

Variable

Inductance

Direct Current

(DC)

Degree Of Protection

Increase

Locked

Time

Rotating Knob And

Push Button

Output On

Synergic Mode

Active

Material Thickness

OM-266409 Page 11

Page 16

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Specifications

Input Power

50 VDC Continuum Series Standard:

*See Section 4-4 for detailed information on wire type, wire size, and wire feed speed.

Welding Power

Source Type

Wire Feed Speed Range* Wire Diameter Range

50−1000 ipm

(1.27−25.4mpm)

4-3. Environmental Specifications

A. IP Rating

IP Rating

IP21S

This equipment is designed for indoor use and is not intended to be used or stored outside.

B. Temperature Specifications

Operating Temperature Range Storage Temperature Range

14 to 104 °F (−10 to 40°C) −4 to 131 °F (−20 to 55°C)

.035 To .5/64 in.

(0.9 To 22 mm)

Max Spool Capacity:

18 in. (457 mm)

Max Spool Weight:

60 lb (27 kg)

Welding Circui

Rating

75 Volts

500 Amperes,

100% Duty

Cycle

Overall

Dimensions

Height:

13-13/16 in.

(351 mm)

Width:

17 in.

(432 mm)

Length:

29-11/16 in.

(754 mm)

Weight

61.5 lb

(27.9 kg)

IP21S 2014−06

Temp_2016-07

4-4. Wire Type, Size, And Wire Feed Speed Table

Wire Size .035 .045 .052 .062 5/64

MIG:

Solid Steel

50 To 1000 ipm

Accupulse:

75 To 1000 ipm

Metalcore Steel N/A

Flux cored Steel N/A

MIG:

50 To 1000 ipm

Accupulse:

50 To 1000 ipm

MIG:

50 To 1000 ipm

Accupulse:

50 To 800 ipm

MIG:

200 To 900 ipm

MIG:

50 To 800 ipm

Accupulse:

50 To 800 ipm

MIG:

50 To 900 ipm

Accupulse:

50 To 700 ipm

MIG:

200 To 900 ipm

MIG:

50 To 600 ipm

Accupulse:

50 To 600 ipm

MIG:

50 To 700 ipm

Accupulse:

50 To 600 ipm

MIG:

150 To 800 ipm

N/A

MIG:

100 To 400 ipm

OM-266409 Page 12

Page 17

SECTION 5 − INSTALLATION

5-1. Power Source And Wire Feeder Site Selection

Movement

Location And Airflow

! Do not put feeder where

welding wire hits cylinder.

18 in.

(460 mm)

! 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 2 0 .

! Do not move or operate equipment

where it could tip.

1 Hand Cart Use cart or similar device to move unit. 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond

opposite side of unit. 3 Line Disconnect Device Locate unit near correct input power supply.

18 in.

(460 mm)

Loc_contfeeder 2015-07

OM-266409 Page 13

Page 18

1 Lifting Eye

5-2. Feeder Location

5-3. Mounting Hole Location

When a feeder is installed on top of power source, lift eye is inserted through slot in feeder base.

3.975 in.

(101 mm)

7.95 in.

(202 mm)

2.8 in.

(71 mm)

2.8 in.

(71 mm)

2.8 in.

(71 mm)

Loc_contfeeder 2015-07

. Holes are designed for 3/8 in.

hex head bolts.

2.8 in.

(71 mm)

OM-266409 Page 14

Ref. 266 419-B

Page 19

5-4. Connection Diagram

1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 5 Feeder Cable 6 Electrode Cable 7 Work Cable 8 Volt Sense Lead 9 Welding Gun 10 Workpiece

. Shielding gas pressure not to

exceed 100 psi (689 kPa).

Ref. 301199−TP2

OM-266409 Page 15

Page 20

5-5. Connecting Weld Output Cable

Tools Needed:

3/4 in. (19 mm)

Wire Feeder Side View

with Door Open

! Turn off power before connecting to

weld output tabs or receptacles.

! Failure to properly connect weld

cables may cause excessive heat and start a fire, or damage your machine.

Ensure all connections are tight.

Tab Connection

. Do not place anything between weld

cable terminal and output tab. Make sure that the surfaces of the weld cable terminal and output tab are clean.

1 Positive Connection Terminal 2 Correct Weld Cable Connection For

Single Cable

3 Correct Weld Cable Connection For

2/0 And Larger Double Cables

4 Incorrect Weld Cable Connection

5 Weld Output Terminal Bolt 6 Weld Cable Terminal 7 Supplied Washer 8 Supplied Nut Remove supplied nut and bolt from weld

output terminal. Insert bolt through hole in weld cabl e terminal and hole in weld output terminal. Screw nut onto bolt until weld cable terminal is tight against output terminal. Torque t o 27−33 ft lb (36.6−45 N·m)

5 6 7

5 6

7 8

OM-266409 Page 16

2/0 and larger double cables

Ref. 259 144-A / Ref. 259 120-B

Page 21

5-6. Remote 10 Wire Feeder Control Receptacle RC2 Information

Notes

Socket Socket Information

A +50 Volts DC Common

B +50 Volts DC Common

C Voltage Sense

D +50 Volts DC Power

E +50 Volts DC Power

F ENET Rx −

G ENET Tx −

H Drain

I ENET Tx +

J ENET Rx +

Ref. 259 145-B / Ref. 259 119-A

OM-266409 Page 17

Page 22

5-7. Control Cable Connections

1 10-Socket Control Receptacle RC2 Connect control cable to receptacle on

rear of welding power source and wire feeder.

Welding Power Source

Rear View

5-8. Wire Feeder Lower Front Panel Connections

Wire Feeder

Rear View

Ref. 259 119-A / Ref. 259 145-B

1 Left−hand 4-Socket Gun

Trigger Receptacle

2 Right-hand 4-Socket Gun

Trigger Receptacle

Connect gun trigger plug to appropriate receptacle on feeder.

OM-266409 Page 18

1 2

Ref. 259 145-B

Page 23

5-9. Shielding Gas Hose Connection

1 Right−hand Shielding Gas

Fitting

1 Left−hand Shielding Gas

Fitting

Connect hose from shielding gas supply to fitting on rear of feeder.

1 2

5-10. Jog/Retract Switch

Wire Feeder Rear View

301199−TP4

1 Jog/Retract Switch 2 Jog Symbol Press Jog/Retract switch to the

right to Jog wire. Jog switch will feed wire through mig gun during installation without energizing the weld output.

3 Retract Symbol Press Jog/Retract switch to the left

to retract wire. Retract switch will feed wire backward.

. If using the retract button to re-

spool wire, the wire spool will need to be manually turned to ensure proper respooling.

Wire Drive Assembly

Ref. 259 144-A

OM-266409 Page 19

Page 24

5-11. Rotating Drive Assembly

1 Retaining Knob And Pin 2 Adjustment Holes (8) Each hole location is spaced at 5

degree increments. There are a total of eight holes for a range of 40 degrees. The second hole from the bottom positions the wire drive assembly parallel with the feeder base.

To rotate the drive assembly, pull retaining knob out and hold it while rotating drive assembly. Release knob at desired position to lock drive assembly in place.

3 Wire Angle at Drive Assembly Rotate the drive assembly to re-

duce bends in the mig gun cable. Wire can b e s e t u p t o f e e d o ff either

the top or bottom of wire spool. Select the option that results in the straightest possible path into drive assembly.

Wire Feeds Off Bottom Of Spool

Good

Bad

Wire Feeds Off Top Of Spool

OM-266409 Page 20

Ref. 259 144-A / 269 820-A

Page 25

-12. Installing Welding Gun

1 Power Clamp Knob

Installing gun with

Accu-Mate connection

Installing gun without

Accu-Mate connection

2 Gun Locking Tab 3 Gun Locking Tab Rotated 180

Degrees 4 Power Pin Groove 5 Gun Connection End

Installing gun with Accu-Mate connection

Loosen power clamp knob to allow power pin of gun to clear the gun locking tab.

Push power pin into power clamp as far as possible to align the groove in the power pin of the gun with the gun locking tab.

Secure gun by tightening power clamp knob.

Installing gun without AccuMate connection

When using a gun without the groove in the power pin, loosen power clamp knob and rotate gun locking tab 180 degrees. This prevents the locking tab from extending into the power pin gun connection.

Push power pin into power clamp as far as possible.

Secure gun by tightening power clamp knob.

6 Gun Control Cable Insert plug into Gun Control

receptacle, and tighten threaded collar.

Ref. 301199−TP5 / ref. 270 026-A / Ref. 260233-B

OM-266409 Page 21

Page 26

5-13. Installing Wire Guides And Drive Rolls

Installing Wire Guide And Drive Rolls

1 Drive Roll Tension Assembly Open tension assembly. 2 Drive Roll Bracket Screw 3 Drive Roll Bracket 4 Drive Roll Carrier And Securing Ring Remove bracket screw. Remove drive roll bracket. 5 Drive Roll Rotate securing rings until tabs line up with

grooves in drive rolls. Remove drive rolls from carriers.

6 Ball And Spring Assembly 7 Anti-Wear Guide 8 Inlet Wire Guide

9 Thumb Screw Install inlet wire guide into anti-wear guide,

and secure with setscrew. Loosen thumb screw. Push inlet guide into opening until groove

aligns with thumb screw. Tighten thumb screw to secure inlet guide.

10 Intermediate Wire Guide

. Shoulder on intermediate wire guide

faces to rear of drive housing.

Push intermediate guide into opening until groove is secured by ball and spring assembly.

Install drive rolls and drive roll bracket. Secure bracket with screw.

11 Upper Drive Roll Shaft

Ref. 260233-B / Ref. 269 820-A

Pull drive roll shaft and remove drive roll carrier. Install drive roll, rotate securing ring until i t stops at a detent position, place carrier back into tension assembly bracket, and secure carrier with drive roll shaft. Do the same for the remaining tension assembly.

. Never close Tension Assembly if Drive

Roll Bracket (3) is removed.

Aligning Wire Guide And Drive Rolls

Self-aligning drive rolls do not require any manual adjustment.

Cleaning Drive Rolls

Remove drive rolls, and clean grooves using a wire brush.

Close drive assembly cover.

OM-266409 Page 22

Page 27

-14. Installing And Threading Welding Wire

Install wire guides and anti-wear guide.

Install drive rolls.

Tools Nee d e d :

. Hold wire tightly to keep it from unraveling.

6 in.

Install wire spool. Adjust tension nut so wire is taut when wire feed stops.

Pull and hold wire; cut off end.

(150 mm)

Pressure

Indicator

Pressure

Adjust

Scale

. For best wire feeding performance, be

sure that the outlet cable has the proper size liner for the welding wire size being used. Also, when the gun is installed, the liner extending from the back of the gun should be as close to the drive rolls as possible, without touching.

Install gun. Lay gun cable out straight. Cut off end of wire. Push wire through guides up to drive rolls; continue to hold wire. Press Jog button t o feed wire out gun.

Back Of Gun

Drive Rolls

End Of Liner

No Wire Slip

NONCONDUCTIVE

SURFACE

Wire Slips

NONCONDUCTIVE

SURFACE

. For soft wire or small diameter stainless

steel wire, reduce drive roll pressure on the rear roll to half that of the front rolls.

. To adjust drive roll pressure, hold nozzle

about 2 in. (51 mm) from nonconductive surface and press gun trigger to feed wire against surface. Tighten knob so wire does not slip. Do not overtighten. If contact tip is completely blocked, wire should slip at the feeder (see pressure adjustment above).Cut wire off. Close cover.

Ref. 156 929-A / Ref. 259 145-B / Ref. 156 930 / 242 517-A

OM-266409 Page 23

Page 28

5-15. Wire Feeder User Interface

1213 14 15

Ref. 266 061-B

OM-266409 Page 24

Page 29

5-16. Description Of Front Panel Controls (See Section 5-15)

1 Memory D i s p l a y The Memory display shows the active weld

program. The range is from 0001 to 9999. 2 Memory/Variable Adjustment Knob Use this knob to select a program number

or increase/decrease the variable shown in the Memory display.

3 Arc Control Button The Arc Control button is process depen-

dent. It allows user to change the variable that appears on the Values/Parameters display, such as inductance, DIG, RMD (ball size) or trim. The range can be +/− depending on the process.

4 Memory 1-8 Buttons And LEDs Use these buttons to select a stored

program f r o m t h e w e l d p r o gram library data. The LED will indicate which program is selected and active. The Variables/Parameters display will show weld program library summary data for the selected program.

5 Soft Key Buttons Use these buttons to navigate the menus

appearing in the LCD display (See Section 5-18).

6 Scroll Knob And Select/Save Button Rotate this knob to scroll available options

or increase/decrease the variable shown in the LCD display.

Pressing this knob acts as a Select/Save

button. Press the button to select options available in the LCD display

7 Values/Parameters LCD Display This display shows all values and parame-

ters that have been selected using the Soft Key buttons and the Scroll knob and Save/ Select button.

8 Amperage/Wire Feed Speed Display This display shows amperage, or wire feed

speed depending on the process selected. 9 Amperage/Wire Feed Speed/Material

Thickness Adjustment Knob

Use this knob to increase/decrease amperage, wire feed speed, or material thickness depending on the process selection. These values appear on the Amperage/Wire Feed Speed/Material Thickness display.

10 Voltage/Arc Length/Inductance/Arc

Adjust/RMD Display

This display shows voltage, arc length, inductance, arc adjust or RMD depending on the process selected.

11 Voltage/Arc Control Adjustment Knob Use this knob to increase/decrease voltage

or arc length depending on the process selection. These values appear on the Voltage/Arc Length/Inductance/Arc Adjust/ RMD display.

12 Arc Length Indicator LED illuminates to show that arc length

function is active.

13 Voltage Indicator LED illuminates to show that the voltage

function is active. 14 Synergic Mode Active Indicator LED illuminates to show that a synergic

weld process is active. 15 Amperage Indicator LED illuminates to show that a SMAW,

GMAW or CAG process is selected. Values appear on the Voltage/Arc Length/Inductance/Arc Adjust/RMD display.

16 Wire Feed Speed Indicator LED illuminates to show that a GMAW or

GMAW-P weld process is selected. Values appear o n the Amperage/Wire Feed Speed/ Material Thickness display.

17 Material Thickness Indicator This feature will be functional in a later soft-

ware release. 18 Output ON Indicator LED illuminates to show that open circuit

voltage i s present at the weld output terminals.

19 USB Port Use this port for all USB related functions

(See Section 5-28). 20 Parameter Lock Indicator LED illuminates to show weld parameters

are locked and active.

* Disabled or not available.

OM-266409 Page 25

Page 30

5-17. Wire Feeder Lower Panel Controls

21 43143 3

1 Cold Wire Jog Button Allows the operator to feed wire through

gun when changing wire spools. Weld output remains off while using cold wire jog button.

2 Trigger Control Button Allows operator to cycle through different

trigger options. See Section 5-23 .

3 Left and Right-Hand TH Indicator Trigger Hold (TH) allows the operator to

start a welding operation by pressing the gun trigger and holding for a preset time period (see Setup Menu features). After the set time elapses the trigger latches and the operator can release the trigger and the welding operation will continue. When the operator presses and releases the trigger, the welding operation will discontinue.

276376A

4 Purge Button Allows operator to purge gas line. To

change amount of purge time (See Section 5-24).

OM-266409 Page 26

Page 31

5-18. LCD Home Screen

Home

Internet

Accupulse

.035 Steel E70 Ar 90 CO2 10

Ref 266 061-A

5 6 7

Logs StatusSetup System

WiFi Ethernet

1 Directory Indicator Displays the directory path of curren

screen. 2 Program Number Displays the current weld program numbe

and which side of feeder is active. 3 Program Information Displays the process type, wire diameter

wire type and alloy, and gas mixture as signed to t h e current weld program.

4 Setup Soft Key Press Setup soft key to enter the Setup

menu screen. Setup Menu screen allows weld programs to be created or changed For more information see Section 5-19.

5 Logs Soft Key Press Logs soft key to enter Logs menu

screen. For more information see Section 5-20.

6 Status Soft Key Press Status soft key to enter the Status

menu screen. For more information see Section 5- 21.

7 System Soft Key Press System Soft Key to enter System

menu screen. System menu allows access to System Reset, USB, and board software revision functions. For more information see Section 5-26.

8 Network Connection Indicator Displays the type of network connection

being used. 9 Internet Displayed when Insight Core is enabled.

5-19. Setup Menu

Home > Setup

Load New Process Trigger Configuration Weld Sequence Configuration Feedback Configuration

Home

Setup Menu

Back

1 Directory Indicator Displays the current directory path. 2 Menu Name Displays the current menu name. 3 Scroll Knob and Select/Save Button Rotate knob to change active option. Active op-

tion will have black circle next to it while inactive options will be white. Press the knob to select the active option.

4 Options Load New Process− Add or make changes to a

weld program. See Section 5-22. Trigger Configuration- Select and edit dual

schedule, trigger dual schedule, 4T, and trigger

hold features. See Section 5-23. Weld Sequence Configuration- Change differen

aspects of the weld sequence such as preflow, start amperage, crater, and post flow. See Section 5-24.

Feedback Configuration- Set voltage feedback method t o stud sense or sense lead. See Section 5-25.

5 Home Soft Key Press Home soft key to return to Home menu

screen.

Ref 266 061-A

OM-266409 Page 27

Page 32

5-20. Logs Menu

Home > Logs

Error Log Boot Log

Home

Logs Menu

Back

1 Directory Indicator Displays the current directory path. 2 Menu Name Displays the current menu name. 3 Scroll Knob and Select/Save

Button

Rotate knob to change active option. Active option will have black circle next to it while inactive options will be white. Press the knob to select the active option.

4 Options Error Log− Displays a list of the last er-

rors the unit has detected. Use the

Scroll Knob to scroll through the list. From the Error log screen press the Home soft key to return to the Home screen, or the Logs Soft key to return to the Logs Menu.

Boot Log− Displays the sequence and status of events that occured during the boot process.

5 Home Soft Key Press Home soft key to return to Home

menu screen.

Ref 266 061-A

5-21. Status Menu

Home > Status

HeatInput[kJńin(kJńmm)] +

Load Bank Mode> Off Accu‐Power Mode> Off Actual / Command> Off

Home

Status Menu

Back

Power(kJńs)xArcTime(s)

WeldBeadLength[in(mm)]

1 Directory Indicator Displays the current directory path. 2 Menu Name Displays the current menu name. 3 Scroll Knob and Select/Save Button Rotate knob to change active option. Ac-

tive option will have black circle next to it while inactive options will be white. Press the knob to select the active option.

4 Options Load Bank Mode- Used to calibrate meters

or test equipment when servicing.

Accu-Power Mode- Displays instantaneous power on wire feed speed display in kilojoules per second to the nearest tenth, updated once per second while welding. After the weld, instantaneous power is displayed for approximately ten seconds before the display changes back to wire feed speed. I f wire feed speed is adjusted during the weld operation, the display will show wire feed speed while being adjusted and will revert back to instantaneous power after adjustment has been made.

T o calculate weld heat input, multiply the i nstantaneous power by the arc time then divide by weld bead length, see equation.

Actual / Command− V alues displayed while welding can can be set to display either actual values or command values set by user.

5 Home Soft Key Press Home soft key to return to Home

menu screen.

Ref 266 061-A

OM-266409 Page 28

Page 33

5-22. Creating, Changing And Saving a Weld Program

Home > Setup

Setup Menu

Load New Process Trigger Configuration Weld Sequence Configuration Feedback Configuration

Home

Back

At the Home screen, using either the memory adjustment knob or memory buttons, select the program number to be used.

From the Home screen, press the Setup softkey.

In the Setup menu rotate the scroll knob to make Load New Process the active option. Press the knob to select Load New Process.

Follow screen prompts. Step 1- Select Wire Type Step 2- Select Wire Alloy Step 3- Select Wire Size Step 4- Select Gas Mixture Step 5- Select Process After selecting process, the display will

read Process Loading. At 100% the program is saved and ready to use.

Ref 266 061-A

5-23. Trigger Configuration

Home > Setup > Trigger Config

Program # 1

Dual Schedule

Trigger Dual Schedule

Trigger Program Select

Trigger Hold

Home

Setup

Program # 2

Dual Schedule

Trigger Dual Schedule

Trigger Program Select

Trigger Hold

Edit Back

In the Setup menu, rotate the scroll knob to make Trigger Configuration the active option. Press the scroll knob to select Trigger Configuration.

. All programs are paired in numeri-

cal order for dual schedule functions. Program 1 and 2 are paired, program 3 and 4 are paired, etc.

Select desired trigger function using the scroll knob.

Ref 266 061-A

OM-266409 Page 29

Page 34

5-24. Weld Sequence Configuration

Home > Setup > Sequence

Sequence Select ‐ Program 1

Preflow ‐ Disabled Start ‐ Disabled Start Ramp ‐ Disabled Weld ‐ Enabled Crater Ramp ‐ Disabled Crater ‐ Disabled

Retract ‐ Disabled Postflow ‐ Disabled

Home

Setup

Edit

At the Home screen, use either the memory adjustment knob or memory buttons t o select the program number to be changed.

From the Home screen, press the Setup softkey.

In the Setup menu, rotate the scroll knob to make Weld Sequence Configuration the active option. Press the scroll knob to select Weld Sequence Configuration.

In the weld sequence configuration screen, rotate the scroll knob to desired function. Press the scroll knob to either enable or disable the function.

With the desired function active, press the Edit softkey to change the functions corresponding parameters:

Preflow- Adjust the length of time gas flows before w e l d b e g i n s .

Start- Adjust voltage, wirefeed speed, time and inductance used for starting weld.

Start Ramp- Adjust the length of time weld takes from start to weld parameters.

Weld- Adjust the voltage, wirefeed speed, time, and inductance.

Crater Ramp- Adjust the length of time from weld to crater parameters.

Crater- Adjust the voltage, wirefeed speed, time, and inductance for crater settings.

Retract- Set the speed and the amount of time the wire retracts after weld.

Postflow- Adjust the amount of time gas flows after the weld.

Preflow

Trigger

Pressed

OM-266409 Page 30

Time

Start

Start Time

Weld

Trigger

Released

Crater

Time

Retract

Time

PostflowCrater

Postflow

Time

Sequence

Time

End

Ref 266 061-A

Page 35

5-25. Feedback Configuration

2 3

Home > Setup > Feedback Configuration

Feedback Configuration

Active > Sense Lead

Change voltage feedback method:

Stud Sense Sense Lead

Home

Back

1 Directory Indicator Displays the current directory path. 2 Menu Name Displays the current menu name. 3 Active Indicator Displays the active feedback method. 4 Scroll Knob and Select/Save

Button

Rotate knob to change active option. Active option will have black circle next to it while inactive options will be white. Press the knob to select the active option.

5 Options Stud Sense- Current feedback mea-

surement i s taken at the output studs of the welding power source.

Sense Lead- Current feedback measurement i s taken with a volt sense lead.

6 Home Soft Key Press Home soft key to return to Home

menu screen.

5-26. System Menu

Home > System

Factory Reset USB Functions System Software Revision Network Settings Machine Serial Number

Home

System Menu

Back

Ref 266 061-A

1 Directory Indicator Displays the current directory path. 2 Menu Name Displays the current menu name. 3 Scroll Knob and Select/Save

Button

Rotate knob to change active option. Active option will have black circle next to it while inactive options will be white. Press the knob to select the active option.

4 Options

Factory Reset- Allows user to reset all values to factory defaults (See Section 5-27).

USB Functions- Update software and load or save weld programs with a USB (See Section 5-28).

System Software Revision- Displays the current software revision of the welding system.

Network Settings- Displays information about the network connections such as IP Address.

Machine Serial Number- Displays the serial number of the unit.

5 Home Soft Key Press Home soft key to return to Home

menu screen.

Ref 266 061-A

OM-266409 Page 31

Page 36

5-27. Factory Reset

Home > System > Factory Reset

Perform Factory Reset?

Factory Reset

No Yes

From the Home screen, press the System softkey.

In the System menu rotate the scroll knob to make Factory Reset the active option. Press the knob to select Factory Reset.

At the Factory Reset screen rotate the scroll knob to select Yes. Press the scroll knob to perform a Factory Reset.

Display will return to the Home screen when Factory Reset is complete.

Home

5-28. USB Functions

Home > System > USB

Write to system Write to USB

Home

USB Functions

System

Back

Ref 266 061-A

From the Home screen, press the System softkey.

In the System menu rotate the scroll knob to make USB Functions the active option. Press the knob to select USB Functions.

Options Write to system- Use a USB key to up-

date unit software and weld programs. Write to USBSystem Settings− Save user created

weld programs to a USB key. User settings can then be loaded on other units, or restored on the current unit.

License Key− A vailable in Insight Core enabled units. Save license key to USB when registering Insight Core.

Diagnostic Files−Available in Insight Core enabled units. Save diagnostic files to be sent back to Miller Service Representatives.

OM-266409 Page 32

Ref 266 061-A

Page 37

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

Notes

6-1. Routine Maintenance

Every

Months

Every

Months

! Disconnect power

before maintaining.

n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent

l Unreadable Labels ~ Weld Terminals nl W eld Cables nl Gun Cables

nl Cords nl Cracked Parts ~ Weld Connections n Tighten Weld Cable

Connections

l Damaged Gas Hose

. Maintain more often

during severe conditions.

Reference

~ Drive Rolls ~ Inside Unit

OM-266409 Page 33

Page 38

6-2. Error Code Troubleshooting Description And Tables

ERR BTN STUK

3 4

1 LED Display Message

Displays a short message describing the error or where the error is occurring. Some messages may represent multiple different errors. For more specific error information see the LCD Display Message.

2 Message Type

There are three types of messages that will be displayed.

ERROR

Button on UI stuck

Make sure all buttons are clear

If error persists, please contact support.

Logs

ERROR- The system has experienced a fault that must be addressed before continuing use.

MESSAGE- No fault has occurred, but some action must be taken before resuming use of the welding system. For instance, input power may need to be cycled after loading new software.

WARNING- There is something that should be addressed before continuing. For instance, the volt sense lead connection has been lost.

Ref. 266 061-B

3 LCD Display Message Provides more information about the mes-

sage being displayed. 4 LCD Solution Message Describes the action needed to clear the

message or fault being experienced. 5 Logs Soft Key Pressing th e L o g s s o f t k e y w i l l t a k e t h e u s-

er to the Logs Menu (See Section 5-20). From the Logs Menu it is possible to access the Error Log. The LCD Error Log Messages are stored in the Error Log.

OM-266409 Page 34

Page 39

LED Display

Message

WELD WAIT ERROR Unit was not ready for a weld se-

ERR OVERTEMP ERROR Welding power source has overheated Allow unit too cool then cycle

E STOP ERROR Emergency stop activated Reset the emergency stop

OVER CURRENT ERROR Welding power source primary draw

CYCLE POWER MESSAGE The unit requires a power cycle Cycle power on the power

OVER POWER ERROR SLF TST ERR ERROR Welder failed self test Cycle power on the power

ERR INPT PWR ERROR Input Power Problem Ensure your primary voltage is

ERR FDR ERROR Feeder Power Problem Cycle power on the power

ERR AUX PWR ERROR AUX Power Problem Cycle power on the power

ERR THERM ERROR Thermal System Problem Cycle power on the power

ERR PWR SRC ERROR Welder Power Source Problem Cycle power on the power

ERR WFS ERROR Actual WFS does not match command Press button to clear error Wire Speed Error ERR STRT ERROR Trigger held too long without arc Press button to clear error Arc Start Error ERR STOP ERROR Potential obstruction in wire feed sys-

ERR GAS FLW ERROR No gas flow to the gun Check gas connections Gas Flow Error ERR COOL FLW ERROR No coolant flow in water system Check water cooling system Coolant Flow Error ERR GND CRNT ERROR Weld current detected in earth ground Check and repair feeder weld

ERR WIR STUK ERROR Wire stick to workpiece at the end of

ERR ARC ERROR Arc Outage occurred Check wire feeder and power

ERR TRG STUK ERROR Trigger held during power up Release trigger and cycle

ERR SOFTWARE ERROR Incompatible software detected in the

ERR FEEDER ERROR Feeder peripheral malfunction Cycle power on the power

ERR COMM FDR ERROR Feeder Lost Comms to Arc Controller Check the control cable Feeder lost comms to AC ERR FDR PWR ERROR Feeder power fault Cycle power on the power

ERR FDR PWR ERROR Feeder power fault Cycle power on the power

ERR FDR RLY ERROR Feeder power relay stuck open Cycle power on the power

ERR FDR ETH ERROR Feeder Ethernet switch malfunction Cycle power on the power

ERR FEEDER ERROR Feeder peripheral malfunction Cycle power on the power

Message

Type

LCD Display Message

quence

too high

tem

the weld

system

LCD Solution

Message

Press button to clear error Weld Wait Error

power

button Check input primary then cy-

cle power

source

correct

source

Check wire feed and wire drive systems

connections Break/Cut wire away from

workpiece

source

power Update software Incompatible Software Error

source

LCD Error Log

Message

Overtemp Error

E Stop

Primary Overcurrent

Cycle Power Error

Self Test Error

Input Power Problem

Feeder Power Problem

AUX Power Problem

Thermal System Problem

Power Source Problem

Arc Stop Error

Earth Ground Current Error

Wire Stuck Error

Arc Outage Error

Trigger Stuck Error

Feeder EEPROM Error

Feeder USART1 Error

Feeder bus overcurrent error

Feeder bus current fault

Feeder relay stuck open

Feeder Ethernet switch error

Feeder USART3 Error

Feeder USART2 Error

Feeder SPI2 Error

OM-266409 Page 35

Page 40

LED Display

Message

ERR FDR TACH ERROR Feeder has lost tachometer wire

ERR BTN STUK ERROR Button on UI stuck Make sure all buttons are

ERR COMM UI ERROR UI Lost Comms to the Sequencer Check the control cable UI lost comms to Seq FACTORY RST ERROR Factory Reset Complete Cycle power on the power

UNUSED 218 ERROR Unused Error #218 Cycle power on the power

ERR INPT PWR ERROR Must use three phase primary power Check primary connections Single Phase Error ERR INPT PWR ERROR Primary input voltage too high Check primary connections High Input Voltage Error ERR INPT PWR ERROR Primary input voltage too low Check primary connections Low Input Voltage Error UNUSED 222 ERROR Unused Error #222 Cycle power on the power

ERR FEEDER ERROR Feeder input voltage too high Cycle power on the power

ERR FEEDER ERROR Feeder input voltage too low Cycle power on the power

UNUSED 225 ERROR Unused Error #225 Cycle power on the power

ERR AUX PWR ERROR Too much current draw from AUX

ERR AUX PWR ERROR AUX power module overheated Cycle power on the power

ERR AUX PWR ERROR AUX power voltage too high Cycle power on the power

ERR AUX PWR ERROR AUX power voltage too low Cycle power on the power

UNUSED 230 ERROR Unused Error #230 Cycle power on the power

ERR THERM 1 ERROR Thermistor 1 overtemp Allow welder to cool then cy-

ERR THERM 2 ERROR Thermistor 2 overtemp Allow welder to cool then cy-

ERR THERM 3 ERROR Thermistor 3 overtemp Allow welder to cool then cy-

ERR THERM 1 ERROR Thermistor 1 shorted Cycle power on the power

ERR THERM 2 ERROR Thermistor 2 shorted Cycle power on the power

ERR THERM 3 ERROR Thermistor 3 shorted Cycle power on the power

ERR THERM 1 ERROR Thermistor 1 open Cycle power on the power

ERR THERM 2 ERROR Thermistor 2 open Cycle power on the power

ERR THERM 3 ERROR Thermistor 3 open Cycle power on the power

UNUSED 240 ERROR Unused Error #240 Cycle power on the power

ERR PWR SRC ERROR Invalid device configuration Cycle power on the power

ERR PWR SRC ERROR Output current sensor malfunction Cycle power on the power

ERR PWR SRC ERROR Inverter −15V power supply out of reg-

ERR PWR SRC ERROR Inverter +15V power supply out of reg-

OM-266409 Page 36

Message

Type

LCD Display Message

speed feedback

power port

ulation

LCD Solution

Message

clear

source

source Cycle power on the power

source

cle power

source

source Cycle power on the power

source

LCD Error Log

Message

Feeder lost tach signal error

UI Button Stuck

Factory Reset

Unused Error #218

Unused Error #222

Feeder Voltage High Error

Feeder Voltage Low Error

Unused Error #225

AUX Power Overcurrent Error

AUX Power Overtemp Error

AUX Voltage High Error

AUX Voltage Low Error

Unused Error #230

THERM1 Overtemp Error

THERM2 Overtemp Error

THERM3 Overtemp Error

THERM1 Shorted Error

THERM2 Shorted Error

THERM3 Shorted Error

THERM1 Open Error

THERM2 Open Error

THERM3 Open Error

Unused Error #240

Invalid Power Source Config

Output Current Sensor Error

Inverter −15V Power Error

Inverter +15V Power Error

Page 41

LED Display

Message

ERR PWR SRC ERROR Invalid inverter device configuration Cycle power on the power

ERR PWR SRC ERROR Inverter primary CT error Cycle power on the power

ERR PWR SRC ERROR Boost fault Cycle power on the power

ERR PWR SRC ERROR Boost contactor error Cycle power on the power

ERR PWR SRC ERROR Boost CS1 current error Cycle power on the power

ERR PWR SRC ERROR Boost CS2 current error Cycle power on the power

ERR PWR SRC ERROR Boost CS3 current error Cycle power on the power

ERR PWR SRC ERROR Boost CS4 current error Cycle power on the power

ERR PWR SRC ERROR Boost current balance error Cycle power on the power

ERR PWR SRC ERROR Boost overcurrent error Cycle power on the power

ERR PWR SRC ERROR Boost precharge error Cycle power on the power

ERR PWR SRC ERROR Boost bus balance error Cycle power on the power

ERR PWR SRC ERROR Boost bottom bus cap voltage high Cycle power on the power

ERR PWR SRC ERROR Boost top bus cap voltage high Cycle power on the power

ERR PWR SRC ERROR Invalid boost device configuration Cycle power on the power

ERR PWR SRC ERROR Boost −15V power supply out of regu-

ERR PWR SRC ERROR Boost −24V power supply out of regu-

ERR PWR SRC ERROR Boost +15V power supply out of regu-

WRN VSNS LOS WARNING Lost volt sense lead feedback Inspect volt sense lead for

ERR UNKNOWN ERROR An unknown error has occurred Update software Unknown Error

Message

Type

LCD Display Message

lation

LCD Solution

Message

source

source Cycle power on the power

source

break

LCD Error Log

Message

Invalid Inverter Config

Inverter Primary CT Error

Boost Fault Error

Boost Contactor Error

Boost CS1 Error

Boost CS2 Error

Boost CS3 Error

Boost CS4 Error

Boost Current Balance Error

Boost Overcurrent Error

Boost Precharge Error

Boost Bus Balance Error

Boost Bottom Bus Cap V High

Boost Top Bus Cap V High

Invalid Boost Config

Boost −15V Power Error

Boost −24V Power Error

Boost +15V Power Error

Vsense Fallback Warning

OM-266409 Page 37

Page 42

6-3. Troubleshooting

Notes

Trouble Remedy

! Disconnect power before troubleshooting

Wire feeds, shielding gas flows, but electrode wire is not energized.

Electrode wire feeding stops or feeds erratically during welding.

Motor runs slowly. Check for correct input voltage. Wire feeder power is on, displays light

up, but unit is inoperative.

Check and secure weld cable connections (see Section 5-5).

Check gun trigger connection. See gun Owner’s Manual. Check gun trigger. See gun Owner’s Manual. Readjust hub tension and drive roll pressure (see Section 5-14). Change to correct size drive roll (see Section 5-13). Clean or replace dirty or worn drive roll. Incorrect size or worn wire guides. Replace contact tip or liner. See gun Owner’s Manual. Remove weld spatter or foreign matter from around nozzle opening. Have Factory Authorized Service Agency check drive motor or motor control board PC1.

Check welding gun trigger leads for continuity, and repair leads or replace gun.

OM-266409 Page 38

Page 43

Notes

OM-266409 Page 39

Page 44

SECTION 7 − ELECTRICAL DIAGRAM

OM-266409 Page 40

Figure 7-1. Circuit Diagram

Page 45

267 896-B

OM-266409 Page 41

Page 46

SECTION 8 − PARTS LIST

. Hardware i s common and

not available unless listed.

14 - Figure 8-4

12Figure 8-3

15 - Figure 10-5

10 - Figure 8-2

13 - Figure 8-7

271 901-B

OM-266409 Page 42

Figure 8-1. Main Assembly

Page 47

Part

Dia.

Item

No.

Mkgs.

No.

Description

Figure 8-1. Main Assembly

1 266419 Base, Feeder Machined 1... .......... .. ...........................................

2 266181 Support, A−Frame 2... .......... .. ................................................

3 257227 Bracket, Support A−Frame 1... .......... .. ........................................

4 +269642 Door, Drive 2... ......... .. .....................................................

5 270991 Insulator, Mylar .014x5.000x9.000 1... .......... ... ................................

6 258742 Label, Warning Moving Parts 1... .......... ... .....................................

7 269889 Label, Caution Pinch Point 1... .......... ... .......................................

8 +269288 Wrapper, Feeder Continuum 1... ......... .. .......................................

9 269890 Label, Warning General Precautionary (CE/Domestic) 1... .......... ... ...............

10 +Figure 8-2 Panel Assy, Front Dual 4 Pin 1... ....... .. .......................................

11 269731 Label, Warning Hot Surfaces And Moving Parts 2... .......... ... .....................

12 Figure 8-3 Panel Assy, Rear Dual 1... ........ .. ...........................................

13 Figure 8-7 Assy, UI 1... ........ .. ........................................................

14 Figure 8-4 Drive Assy, Wire Dual Lh 1... ........ .. .........................................

15 Figure 8-5 Drive Assy, Wire Dual Rh 1... ........ .. ..........................................

16 See Inset Assy, Power Pin Block Lh Or Rh 2... ......... .. ...................................

17 073432 Ftg, Hose Brs Barbed M 3/16 Tbg X 1/8 Npt 1... .......... ... .......................

18 268570 Block, Power Pin Lh 1... .......... ... ............................................

19 268571 Block, Power Pin Rh 1... .......... ... ............................................

20 234073 Pin, Hinge 1... .......... ... ....................................................

21 251557 Spring, Cprsn .210 Od X .026 Wire X 1.000 Pld 1... .......... ... ....................

22 262691 Clamp, Power Pin 1... .......... ... ..............................................

23 262703 Lock, Power Pin 1... .......... ... ................................................

24 151437 Knob, T 1.500 Bar W/.312−18 Stud 1.125 Lg Plstc 1... .......... ... ................

25 151828 Pin, Cotter Hair .042 X .750 1... .......... ... .....................................

26 267482 Bracket, Door 2... .......... .. ....................................................

27 268704 Hub and Spindle Assy 2... .......... .. ............................................

28 265876 Shaft, Spool Hub 1... .......... ... ...............................................

29 231211 Washer, Anti−Turn 2... ........... ... .............................................

30 010191 Washer, Flat .656idx1.500odx.125t Fbr 2... .......... ... ...........................

31 058628 Washer, Brake Stl 2... .......... ... ..............................................

32 058428 Hub, Spool 1... .......... ... ....................................................

33 058427 Ring, Retaining Spool 1... .......... ... ..........................................

34 010233 Spring, Cprsn .970 Od X .120 Wire X 1.250 Pld 1... .......... ... ...................

35 237843 Knob, Brake Adjust (Diecast) 1... .......... ... ....................................

36 089899 Latch, Slide Flush 2... .......... .. ................................................

37 267442 Bracket, Board 1... .......... .. ...................................................

38 PC36 273049 Circuit Card Assy, Motor/Feeder Comm Boom/Dual/Auto 1... .. . .. ..............

39 269633 Bracket, Door Hinge 2... .......... .. ..............................................

40 262770 Bracket, Rear Grommet Cords/Cables 1... .......... .. ..............................

41 266397 Bushing, Snap−in Nyl 1.860 ID x 2.250 Dia Mtg Hole 1... .......... .. ..................

42 057358 Bushing, Snap−in Nyl 1.000 ID x 1.375 Mtg Hole 2... .......... .. .....................

43 267307 Hinge, Door Friction Adjustable 4... .......... .. ....................................

44 S1, S2 216295 Switch, Rocker SPDT .4VA 28VDC (On)-Off-(On) 2... .. . .. ....................

Quanti

+ 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-266409 Page 43

Page 48

. Hardware i s common and

Part

Dia.

Item

not available unless listed.

271 902-B

Figure 8-2. Front Panel Assembly

No.

Mkgs.

No.

Description

Quanti

Figure 8-2. Front Panel Assembly (Figure 8-1, Item 10)

1 266147 Plate, Trigger Dual 4pin 1... .......... .. ...........................................

2 276376 Membrane, Switch Control Continuum Feeder Single 1... .......... .. .................

3 +253528 Bezel, Feeder With Inserts 1... ......... .. ........................................

4 269731 Label, Warning Hot Surfaces And Moving Parts 2... .......... ... .....................

5 253628 Baffle, Front Panel 1... .......... .. ...............................................

6 170647 Bushing, Snap−In Nyl 1.062 Id X 1.500 Mtg Hole Cent 2... .......... .. ................

7 PC41 266157 Circuit Card Assy, Trigger Dual 4pin 1... .. . .. ................................

8 107983 Not Being Used... .......... ..

9 223343 Clip, Wire Stdf .40−.50 Bndl .156hole .031−.078thk 1... .......... .. ...................

10 207152 Nut, 010−32 U−Nut Multi−Thread 2... .......... .. ...................................

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

OM-266409 Page 44

Page 49

. Hardware i s common and

Part

Dia.

Item

not available unless listed.

271 903-B

Figure 8-3. Rear Panel Assembly

No.

Mkgs.

No.

267837

Description

Figure 8-3. Rear Panel Assembly (Figure 8-1, Item 12)

Quanti

1 257622 Panel, Rear Dual 1... .......... .. .................................................

2 GS1,GS2 228035 Valve, 34vdc 1way .750−14 Thd 2mm Orf 100psi 2... . .. ....................

3 211989 Fitting, W/Screen 2... ........... .. ................................................

4 Label, Nameplate (Order By Model and Serial Number) 1... ..................... ...............

5 PC31 272939 Circuit Card Assy, Motor/Feeder Comm W/Prog 1... .. . .. ......................

200814 Hose Assy (Includes) 2................ .. .............................................

6 134834 Hose, SAE .187 ID x .410 OD 1.417... .......... ... ....................................

7 149332 Clamp, Hose .405−.485 Clp Dia 2... .......... ... ..................................

8 107983 Not Being Used... .......... ..

9 220805 Nut, 750−14 NPS 1.48Hex .41H Nyl 2... .......... .. ................................

10 269715 Stand−off Support, PC Card .312/.375w/Post&Lock .50 4... .......... .. ...............

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

OM-266409 Page 45

Page 50

. Hardware i s common and

Part

Dia.

Item

not available unless listed.

9 - Figure 8-6

Figure 8-4. Left-Hand Wire Drive Assembly

No.

Mkgs.

No.

Description

Figure 8-4. Left-Hand Wire Drive Assembly (Figure 8-1, Item 14)

1 255451 Encoder, Optical 1... .......... .. .................................................

261787 Plug, w/Cable For Encoder 1................ .. ........................................

2 M1 257629 Motor, Gear 1/11HP 40VDC R Angle Rh 1... ... .. .. .............................

3 271862 Stand-off, 10-32 X 1.125 Lg .313 Hex Stl M&M 3... .......... .. .......................

4 253589 Hub, Gear 1... .......... .. .......................................................

5 267153 Frame, Drive Assy Machined 1... .......... .. ......................................

6 266421 Spacer, Al .166 Id X .250 Od X .562 Lg 3... .......... .. .............................

7 267162 Plate, Drive Mtg Dual 1... .......... .. .............................................

8 267147 Insulator, Motor Mount Lh 1... .......... .. .........................................

9 Figure 8-6 Drive Assy, Wire No Motor Single 1... ........ .. ..................................

10 263322 Screw, Thumb Stl .250−20 x .500 Pld Nylon Head 1... .......... .. ....................

11 256640 Block, Inlet 1... .......... .. ......................................................

12 266403 Pin, Retractable Spring Plunger Plate Mtg 1... .......... .. ...........................

271 904-A

Quanti

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

OM-266409 Page 46

Page 51

Part

Dia.

Item

. Hardware i s common and

not available unless listed.

9 - Figure 8-6

Figure 8-5. Right-Hand Wire Drive Assembly

No.

Mkgs.

No.

Description

Figure 8-5. Right-Hand Wire Drive Assembly (Figure 8-1, Item 15)

1 255451 Encoder, Optical 1... .......... .. .................................................

261787 Plug, w/Cable For Encoder 1................ .. ........................................

2 M1 257630 Motor, Gear 1/11HP 40VDC R Angle Lh Boom 1... ... .. .. .......................

3 271862 Stand-off, 10-32 X 1.125 Lg .313 Hex Stl M&M 3... .......... .. .......................

4 253589 Hub, Gear 1... .......... .. .......................................................

5 267153 Insulator, Drive Frame 1... .......... .. ............................................

6 266421 Spacer, Al .166 Id X .250 Od X .562 Lg 3... .......... .. .............................

7 267162 Plate, Drive Mtg Dual 1... .......... .. .............................................

8 267179 Insulator, Motor Mount Rh 1... .......... .. .........................................

9 Figure 8-6 Drive Assy, Wire No Motor Single 1... ........ .. ..................................

10 263322 Screw, Thumb Stl .250−20 x .500 Pld Nylon Head 1... .......... .. ....................

11 256640 Block, Inlet 1... .......... .. ......................................................

12 266403 Pin, Retractable Spring Plunger Plate Mtg 1... .......... .. ...........................

272 115-A

Quanti

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

OM-266409 Page 47

Page 52

. Hardware i s common and

Part

Dia.

Item

not available unless listed.

269 727-A

Figure 8-6. Drive Assembly

No.

Mkgs.

No.

267733

Description

Figure 8-6. Drive Assembly (Figure 8-4, Item 9; Figure 8-5, Item 9)

Quanti

1 260262 Assy, Pressure Arm Left 1.. .............. .. ..........................................

2 260263 Assy, Pressure Arm Right 1.. .............. .. ........................................

3 259150 Spring,Double Torsion .408 OD .051 Wire 1.. .............. .. ..........................

4 256877 Pin, Gear Idler 2.. .............. .. ..................................................

5 261793 Pin, Clevis .250 OD X 2.500 Lg W/Groove 2.. .............. .. .........................

6 266830 Carrier, Drive Roll W/Cmpnts 24 Pitch .250 In Shaft 4.. .............. .. ..................

7 260239 Drive Body Assy, Cast 1.. .............. .. ...........................................

8 252217 Knob Assy, Tension Adjust 2.. .............. .. ........................................

9 251473 Gear, Drive Pinion 1.. .............. .. ...............................................

10 258383 Shaft, Drive Roll 2.. .............. .. .................................................

11 263359 Screw, Thumb Stl .312-18 X 1.500 Pld Nylon Head 1.. .............. .. ..................

12 260260 Shaft Assy, Support Cover 1.. .............. .. ........................................

13 151828 Pin, Cotter Hair .042 X .750 2.. .............. .. .....................................

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

OM-266409 Page 48

Page 53

Part

Dia.

Item

. Hardware i s common and

not available unless listed.

Figure 8-7. User Interface

No.

Mkgs.

No.

266850

Description

Figure 8-7. User Interface (Figure 8-1, Item 13)

1 266072 Plate, Ui 1... .......... .. ........................................................

2 266061 Membrane, Switch Control Continuum Ui 1... .......... .. ............................

3 266189 Display, Lcd Tft 320x240 18bit Rgb Pc Tail 1... .......... .. .........................

4 266591 Knob, Encoder 1.250 Dia X 6mm Id Push On W/Spring 2... .......... .. ...............

5 PC34 272938 Circuit Card Assy, Ui W/Program 1... .. . .. ...................................

6 230052 Knob, .840 Dia X 6mm Id W/Spring Clip−4.5 1... .......... .. ........................

7 269555 Knob, .840 Dia X 6mm Id W/Spring Clip−4.5 w/Print 1... .......... .. ..................

8 267343 Cover, USB 1... .......... .. .....................................................

269 786-A

Quanti

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

OM-266409 Page 49

Page 54

”U” GROOVE FOR

ALUMINUM WIRES

CONTAINS NYLON

WIRE GUIDES

”U” COGGED FOR

EXTREMELY SOFT

WIRE OR SOFT*

SHELLED CORED

WIRES

SHELLED

”V” KNURLED FOR

HARD

CORED WIRES

SHELLED

”U” GROOVE FOR

SOFT

CORED WIRES

”V” GROOVE FOR

HARD WIRE

OM-266409 Page 50

WIRE SIZE

.023/.025 in. (0.6 mm) 151024

.030 in. (0.8 mm) 151025

.035 in. (0.9 mm) 151026 151052 243233

.040 in. (1.0 mm) 161190

.045 in. (1.1/1.2 mm) 151027 151037* 151053 151070 243234*

.052 in. (1.3/1.4 mm) 151028 151038 151054 151071

1/16 in. (1.6 mm) 151029 151039 151055 151072 243235

.068/.072 in. (1.8 mm) 151056

5/64 in. (2.0 mm) 151040 151057 151073

3/32 in. (2.4 mm) 151041 151058 151074

7/64 in. (2.8 mm) 151042 151059 151075

1/8 in. (3.2 mm) 151043** 151060** 151076**

Table 10-1. Drive Roll And Wire Guide Kits

*speed wire feeder

*Accommodates .045 and .047 (3/64 in) wire

**Requires a low

Wire Guides Nylon Wire Guides for Feeding Aluminum Wire

Wire Sizes Inlet Guide Intermediate Guide Wire Size Inlet Guide Intermediate Guide

.023 to .040 in. (0.6 to 1.0mm) 221030 149518 .035 in. (0.9mm) 221912 242417

.045 to .052 in. (1.1 to 1.4mm) 221030 149519 .047 in. (1.2mm) 221912 205936

1/16 to 5/64 in. (1.6 to 2mm) 221030 149520 1/16 in. (1.6mm) 221912 205937

3/32 to 7/64 in. (2.4 to 2.8mm) 229919 149521

1/8 in. (3.2mm) 229919 149522

Page 55

Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.

Y our distributor also gives you ...

Service

Y ou 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, 2016

(Equipment with a serial number preface of MG or newer)

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

LIMITED W ARRANTY − 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 W ARRANTY 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. If notification is submitted as an online warranty claim, the claim must include a detailed description of the fault and the troubleshooting steps taken to identify failed components and the cause of their failure.

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 twelve months 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 Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor * Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/Generators

(NOTE: Engines are Warranted Separately by the Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated) * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor * Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified * Automatic Motion Devices * CoolBelt and CoolBand Blower Unit (No Labor) * Desiccant Air Dryer System * External Monitoring Equipment and Sensors * Field Options

(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

* RFCS Foot Controls (Except RFCS-RJ45) * Fume Extractors − Filtair 130, MWX and SWX Series * HF Units * ICE/XT Plasma Cutting Torches (No Labor) * Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted Separately by the Manufacturer.)

* LiveArc Welding Performance Management System * Load Banks * Motor-Driven Guns (except Spoolmate Spoolguns) * PAPR Blower Unit (No Labor) * Positioners and Controllers * Racks * Running Gear/Trailers * Spot Welders * Subarc Wire Drive Assemblies * Water Coolant Systems * TIG Torches (No Labor) * Wireless Remote Foot/Hand Controls and Receivers * Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts * Batteries * Bernard Guns (No Labor) * Tregaskiss Guns (No Labor)

6. 90 Days — Parts * Accessory (Kits) * Canvas Covers * Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls * M-Guns * MIG Guns and Subarc (SAW) Torches * Remote Controls and RFCS-RJ45 * Replacement Parts (No labor) * Roughneck Guns * Spoolmate Spoolguns

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)

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 remedi es ot h er th a n a s s ta t ed he re i n, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 2016-01

Page 56

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-A t t ended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.