Miller CONTINUUM ROI (REMOTE OPERATOR INTERFACE) Owners manual

OM-269551C 2016−04

Processes

MIG (GMAW) Welding

Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)

Description

Wire Feeder

®

Continuum ROI

(Remote Operator Interface)

Visit our website at

www.MillerWelds.com/ams

File: Advanced Manufacturing Systems

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 9001:2000 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

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. Miscellaneous Symbols And Definitions 9..................................................

SECTION 4 − INTRODUCTION 10...............................................................

4-1. Serial Number And Rating Label Location 10................................................

4-2. Specifications 10.......................................................................

SECTION 5 − INSTALLATION 10................................................................

5-1. Mounting Bracket Hole Layout 10..........................................................

5-2. Mounting Remote Operator Interface To Boom 11............................................

5-3. Remote Operator Interface And Wire Drive Installation 11.....................................

5-4. Equipment Connection Diagram 12........................................................

5-5. Remote Operator Interface Connections 13.................................................

5-6. 10-Pin Feeder Receptacle Information 13...................................................

5-7. 10-Pin Welding Power Source Receptacle Information 13.....................................

SECTION 6 − OPERATION 14...................................................................

6-1. User Interface 14.......................................................................

6-2. Description Of Front Panel Controls (See Section 6-1) 15......................................

6-3. LCD Home Screen 16...................................................................

6-4. Setup Menu 16.........................................................................

6-5. Logs Menu 17..........................................................................

6-6. Status Menu 17.........................................................................

6-7. Creating, Changing And Saving a Weld Program 18..........................................

6-8. Trigger Configuration 18..................................................................

6-9. Weld Sequence Configuration 19..........................................................

6-10. Feedback Configuration 20...............................................................

6-11. System Menu 20........................................................................

6-12. Factory Reset 21.......................................................................

6-13. USB Functions 21.......................................................................

6-14. Lower Panel Controls 22.................................................................

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 23.......................................

7-1. Routine Maintenance 23.................................................................

7-2. Error Code Troubleshooting Description And Tables 24........................................

7-3. Troubleshooting 28......................................................................

SECTION 8 − ELECTRICAL DIAGRAM 29........................................................

SECTION 9 − PARTS LIST 30...................................................................

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

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

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 PARTS, 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-269551 Page 1

FUMES AND GASES can be hazardous.

)

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 METAL or 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 off compressed gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

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

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

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

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

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 off 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-269551 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 num-

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.

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

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 carefully 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 jump

start vehicles unless it has a battery charging
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 to 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-269551 Page 3

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 in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

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

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

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

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], 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: [phone], 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: [phone], 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: [phone], web­site: www.ansi.org).

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

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (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: [phone], 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 con-
duct 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-269551 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

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 attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la 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 métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.

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 couper ou le sol.

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 ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est 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-269551 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

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. Leur
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 consommables, les produits de refroidissement, les
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 et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

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

Le rayonnement de l’arc du procédé de soudage génèr

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l
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 rayons visibles et invisibles intenses (ultraviolets

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut

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-269551 Page 6

provoquer leur éclatement. Des étincelles peuvent

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 déclencher un incendie de l’autre côté.

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 souder là où l’air ambiant pourrait contenir des poussières,

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

D Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en 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 ou couper le fil à la pointe de contact.

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.

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 DES
SALETES peuvent provoquer des
blessures dans les yeux.

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

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

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.

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 exploser
si elles sont endommagées.

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

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 le 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 suffi-

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 la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

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

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-

duits inflammables.

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

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

LA CHUTE DE L’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

avant de poursuivre le soudage.

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

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et

les yeux.

D Affûter l’électrode au tungstène uniquement à
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.

LES CHARGES ÉLECTROSTATI­QUES 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 BATTERIE
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 de 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-269551 Page 7

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

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

pements de radio−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 ce 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’État 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

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

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

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

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

Engineering Documents (phone: [phone],
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], 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: [phone], 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: [phone], 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: [phone], web­site: www.ansi.org).

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

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (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: [phone], website:
www.cdc.gov/NIOSH).

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 du 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-269551 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 chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

SECTION 3 − DEFINITIONS

3-1. Miscellaneous Symbols And Definitions

Notes

Purge by Gas

Memory

Arc Control

Push Button

Rotating Knob

And Push Button

V

A

Cold Jog (Inch)

Toward Workpiece

TH

Trigger Hold

USB

Voltage

Amperage

Material

Thickness

Wire Feed

Output On

Arc Length

Synergic Mode

Active

OM-269551 Page 9

SECTION 4 − INTRODUCTION

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

Type of Input

Power

50 Volts DC Continuum Series Standard:

Welding Power

Source Type

Wire Feed Speed Range

50 To 1000 ipm

(1.27 To 25.4 mpm)

SECTION 5 − INSTALLATION

5-1. Mounting Bracket Hole Layout

8.0 in.

(203 mm)

3.0 in.

(76 mm)

4.0 in.

(102 mm)

Wire Diameter

Range

.035 To 5/64 in.

(0.9 To 2 mm)

Max Spool

Weight:

60 lb (27 kg)

Extruded holes in mounting bracket for
1/4 in. self-tapping screws (8).

0.375 in. (9.5 mm)

Welding Circuit

500 Amperes,

Rating

75 Volts,

100% Duty

Cycle

Overall

Dimensions

Length: 3.3 in.

(84 mm)

Width: 8 in.

(203 mm)

Height: 11 in.

(280 mm)

Weight

4.1 lb

(1.86 kg)

OM-269551 Page 10

Top View

6.0 in.

(152 mm)

10.25 in.

(260 mm)

5.781 in.

(147 mm)

Front View Side View

11.093 in.
(282 mm)

Ref.301 227-B

5-2. Mounting Remote Operator Interface To Boom

R

d Wire Drive I

Tools Needed:

2

1

3

4

! Turn Off and disconnect

input power.

1 Remote Operator Interface
2 Mounting Bracket
3 Mounting Plate
4 1/4-20 x 1/2 in. Screw (8)
Attach mounting bracket to mount-

ing plate using four screws.
Attach remote operator interface to

mounting bracket using four 1/4-20
x 1/2 in. screws.

5-3.

3/8 in.

emote Operator Interface An

1

3

3

4

nstallation

2

6

804 165-A

Typical Swingarc installation shown;
however, various installations are
possible depending on the
application.

1 Remote Operator Interface
2 10-Pin Control Cable to Wire

Drive Assembly

3 10-Pin Control Cable to

welding power source.
4 Boom
5 Wire Drive Assembly
6 SwingArc Swivel Assembly

5

4

Ref. 271 204-A

OM-269551 Page 11

5-4. Equipment Connection Diagram

6

14

7

10

9

8

4

11

1

3

12

16

13

15

2

1 Welding Power Source
2 Positive (+) Weld Cable
3 Negative (−) Weld Cable
4 Workpiece
5 Voltage Sensing Lead (Optional)

. Positive (+) voltage sensing lead is con-

tained in the motor cable.

OM-269551 Page 12

5

6 Remote Operator Interface
7 Boom
8 Gun
9 Trigger Connection
10 Shielding Gas Valve
11 Swivel

271 200-A

12 Pipe Post And Base
13 Gas Hose
14 Motor Control/Shielding Gas Valve

Cable
15 Network Feeder Cable
16 Gas Supply And Regulator (Customer

Supplied)

5-5. Remote Operator Interface Connections

1

1 10-Pin Feeder Receptacle
2 10-Pin Welding Power Source

Receptacle

2

5-6. 10-Pin Feeder Receptacle Information

10

H

A

I

B

G

J

F

C

D

E

Pin Pin 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 +

5-7. 10-Pin Welding Power Source Receptacle Information

10

Pin Pin Information

301227−TP3

A +50 Volts DC Common
B +50 Volts DC Common
C Voltage Sense
D +50 Volts DC Power

H

A

I

B

G

J

F

C

D

E

E +50 Volts DC Power
F ENET Rx −

G ENET Tx −
H Drain

I ENET Tx +

J ENET Rx +

OM-269551 Page 13

6-1. User Interface

SECTION 6 − OPERATION

1

2

11

4

7

10

1213 14 15

18

16

8

17

9

20

6

19

3

Ref. 266 061-B

5

OM-269551 Page 14

6-2. Description Of Front Panel Controls (See Section 6-1)

1 Memory Display
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 +/− depend-
ing on the process.

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

program from the weld program 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
6-3).

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 on 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 is present at the weld output termi­nals.

19 USB Port
Use this port for all USB related functions

(See Section 6-13).
20 Parameter Lock Indicator
LED illuminates to show weld parameters

are locked and active.

* Disabled or not available.

OM-269551 Page 15

6-3. LCD Home Screen

Home

1

2

3

Accupulse
.035 Steel E70
Ar 90 CO2 10

4

Ref 266 061-A

9

Internet

WiFi Ethernet

Program # 1

Logs StatusSetup System

5 6 7

1 Directory Indicator
Displays the directory path of current

screen.
2 Program Number
Displays the current weld program

8

number.
3 Program Information
Displays the process type, wire diameter,

wire type and alloy, and gas mixture as­signed to the 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 6-4.

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

screen. For more information
see Section 6-5.

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

menu screen. For more information see
Section 6-6.

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 6-11.

8 Network Connection Indicator
Displays the type of network connection be-

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

6-4. Setup Menu

Home > Setup

1

2

4

5

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 6-7.
Trigger Configuration- Select and edit dual

schedule, trigger dual schedule, 4T, and trigger

3

hold features. See Section 6-8.
Weld Sequence Configuration- Change different

aspects of the weld sequence such as preflow,
start amperage, crater, and post flow.
See Section 6-9.

Feedback Configuration- Set voltage feedback
method to stud sense or sense lead. See Section
6-10.

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

screen.

Ref 266 061-A

OM-269551 Page 16

6-5. Logs Menu

1

5

Home > Logs

2

4

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

3

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

6-6. Status Menu

Home > Status

1

2

4

5

HeatInput[kJńin(kJńmm)] +

Ref 266 061-A

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. 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
Load Bank Mode- Used to calibrate meters

or test equipment when servicing.

3

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. If 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.

To calculate weld heat input, multiply the in­stantaneous power by the arc time then di­vide by weld bead length, see equation.

Actual / Command− Values 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.

OM-269551 Page 17

6-7. 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

6-8. Trigger Configuration

Home > Setup > Trigger Config

Program # 1

Dual Schedule

Trigger Dual Schedule

Trigger Program Select

4T

Trigger Hold

Home

Setup

Program # 2

Dual Schedule

Trigger Dual Schedule

Trigger Program Select

4T

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.

OM-269551 Page 18

Ref 266 061-A

6-9. 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 to 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 weld begins.

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

Preflow

Time

Start

Start
Time

Weld

Weld

Trigger

Released

Crater

Time

Retract

Retract

Time

PostflowCrater

Postflow

Time

Sequence

Time

End

Ref 266 061-A

OM-269551 Page 19

6-10. Feedback Configuration

1

2

3

5

6

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.

4

5 Options
Stud Sense- Current feedback mea-

surement is taken at the output studs of
the welding power source.

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

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

menu screen.

Ref 266 061-A

6-11. System Menu

2

4

5

Home > System

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

Home

1

System 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

3

Factory Reset- Allows user to reset all
values to factory defaults (See Section
6-12).

USB Functions- Update software and
load or save weld programs with a USB
(See Section 6-13).

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-269551 Page 20

6-12. 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

6-13. 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− Available 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.

Ref 266 061-A

OM-269551 Page 21

6-14. Lower Panel Controls

1 243

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 differ-

ent trigger options. See Section 6-8.
3 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.

4 Purge Button
Allows operator to purge gas line. To

change amount of purge time (See Sec­tion 6-9).

Notes

OM-269551 Page 22

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING

7-1. Routine Maintenance

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

Every

3

Months

l Unreadable Labels nl Cracked Parts nl Cords

Every

6

Months

~ Inside Unit

Notes

OR

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

OM-269551 Page 23

7-2. Error Code Troubleshooting Description And Tables

1

ERR BTN STUK

2
3

4

5

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 the Logs soft key will take the us-

er to the Logs Menu (See Section 6-5).
From the Logs Menu it is possible to ac­cess the Error Log. The LCD Error Log
Messages are stored in the Error Log.

OM-269551 Page 24

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 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

ERR FEEDER ERROR Feeder peripheral 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

source

correct

source

source

source

source

Check wire feed and wire
drive systems

connections
Break/Cut wire away from

workpiece

source

power
Update software Incompatible Software Error

source

source

source

source

source

source

source

source

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-269551 Page 25

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-

Message

Type

LCD Display Message

speed feedback

power port

ulation

ulation

LCD Solution

Message

clear

source

source

source

source

source

source
Cycle power on the power

source

source

source

source

source

cle power

cle power

cle power

source

source

source

source

source

source

source

source

source
Cycle power on the power

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

OM-269551 Page 26

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

lation

lation

LCD Solution

Message

source

source

source

source

source

source

source

source

source

source

source

source

source

source

source
Cycle power on the power

source
Cycle power on the power

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-269551 Page 27

7-3. Troubleshooting

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 7-4).

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 Feeder Owner’s Manual.

Change to correct size drive roll. See Feeder Owner’s Manual.

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-269551 Page 28

SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram

251 695-A

OM-269551 Page 29

. Hardware is common and

not available unless listed.

2 - Figure 9-2.

SECTION 9 − PARTS LIST

7

6

5

4

3

8

1

Figure 9-1. Remote Operator Interface

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 9-1. Remote Operator Interface

1 267033 Membrane, Switch Control Continuum Roi 1.. .............. .. ..........................

2 Fig. 9-2. Assy, Ui 1.. ............. .. .......................................................

3 269635 Enclosure, Front Control Box Continuum 1.. .............. .. ...........................

4 210530 Blank, Snap−In Nyl 1.250 Mtg Hole Black 1.. .............. .. ..........................

5 262437 Circuit Card Assy, Feeder 10 Pin Filter 1.. .............. .. .............................

6 261838 Circuit Card Assy, Power Source 10 Pin Filter 1.. .............. .. .......................

7 269636 Panel, Rear Control Box Continuum 1.. .............. .. ...............................

8 251659 Bracket, Mtg Control Box Continuum 1.. .............. .. ...............................

271079 Cable, Ethernet Cat6 Ftp Rj45 14.000 In Lg Right An 2.................... .. .................

PLG4, PLG14 115092 Housing Plug + Skts, (Service Kit) 2....... . .. ................................

PLG21/PLG24,....... .....................................................................................................

PLG9/PLG19 202592 Housing Plug + Skts, (Service Kit) 2.......... . .. ................................

301227−TP2

Quantity

OM-269551 Page 30

5

1

3

2

. Hardware is common and

not available unless listed.

6

8

4

7

Figure 9-2. User Interface

Item

No.

Dia.

Mkgs.

Part

No.

Description

9-2. User Interface (Figure 9-1, Item 2)

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

Quantity

+ 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-269551 Page 31

Notes

Notes

Notes

Warranty Questions?

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

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

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 WARRANTY − Subject to the terms and conditions below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective
date of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace
any warranted parts or components that fail due to such defects in
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed. 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 remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.

miller_warr 2016-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts)
Circuit Diagrams
Welding Process Handbooks

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

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01

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.