Miller D-74 MPA PLUS CONTROL BOX Owners manual CE AND NON CE

OM-247 643B

2012−05

Processes

MIG (GMAW) Welding
MIG (GMAW-P) Welding
Flux Cored (FCAW) W elding
(Gas- And Self-Shielded)

Description

Wire Feeder
Aluminum Push/Pull Capable

D-74 MPa Plus

Control Box

CE And Non-CE Models

Visit our website at

www.MillerWelds.com

File: MIG (GMAW)

From Miller to You

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

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

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

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

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

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

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

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

2-6. Informations relatives aux CEM 9.........................................................

SECTION 3 − DEFINITIONS 11..................................................................

3-1. WEEE Label (For Products Sold Within The EU) 11..........................................

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

SECTION 4 − INSTALLATION 12................................................................

4-1. Important Information Regarding CE Products (Sold Within The EU) 12..........................

4-2. Serial Number And Rating Label Location 12................................................

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

4-4. Equipment Connection Diagram 13........................................................

4-5. Installing Control Box And Adjusting Tilt 14..................................................

4-6. Control Box Connections 14..............................................................

4-7. 14-Pin Plug Information For Connecting Wire Feeder To Power Source 15........................

4-8. Wire Type, Size, And Optimal Wire Feed Speed Table 15......................................

SECTION 5 − OPERATION 16...................................................................

5-1. Power Switch 16........................................................................

5-2. Jog/Purge Switch 16....................................................................

5-3. Front Panel Controls 17..................................................................

5-4. Left Display 18.........................................................................

5-5. Right Display 18........................................................................

5-6. Adjust Control Left/Right 19...............................................................

5-7. Setup Push Button 19...................................................................

5-8. Start Push Button 19....................................................................

5-9. Crater Push Button 19...................................................................

5-10. Left/Right Display Push Button 20.........................................................

5-11. Power Source Selection Menu 20..........................................................

5-12. Operational Terms 21....................................................................

SECTION 6 − SETTING SEQUENCE PARAMETERS 22............................................

6-1. Sequence Parameters In A Program 22.....................................................

SECTION 7 − PROGRAMMING 23...............................................................

7-1. Setup Menu 23.........................................................................

7-2. Setup Menu Level 2 24..................................................................

7-3. Setting A Start Sequence 25..............................................................

7-4. Setting A Crater Fill Sequence 26..........................................................

7-5. Profile Pulse 27.........................................................................

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 28.........................................

8-1. Routine Maintenance 28.................................................................

8-2. Diagnostics 28.........................................................................

8-3. Troubleshooting 29......................................................................

SECTION 9 − ELECTRICAL DIAGRAM 30........................................................

SECTION 10 − PARTS LIST 32..................................................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

D74 MPa Plus Control box (CE) 300739001

Council Directives:

• 2006/95/EC Low Voltage

• 2004/108/EC Electromagnetic Compatibility

Standards:

• IEC 609741:2005 Arc welding equipment – Part 1: Welding power sources

• IEC 609745:2007 Arc welding equipment – Part 5: Wire feeders

• IEC 6097410:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements

• EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,

arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)

Signatory:

April 20, 2012

_____________________________________ ___________________________________________

David A. Werba

MANAGER, PRODUCT DESIGN COMPLIANCE

256449A

Date of Declaration

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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7

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

1-1. Symbol Usage

som 2011−10

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury .

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

D Do not touch live electrical parts.

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

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

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

there is a danger of falling.

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

unit.

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

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a D C manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

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

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

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

. Indicates special instructions.

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

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

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

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced 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.

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 equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-247 643 Page 1

FUMES AND GASES can be hazardous.

F)

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t

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

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

arc to remove welding fumes and gases.

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

and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.

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.

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

contact tip when not in use.

D Wear oil-free protective garments 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.

FLYING ME TA L o r DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

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 protective clothing made from durable, flame-resistant

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

WELDING can cause fire or explosion.

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

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 may 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-247 643 Page 2

workpiece, and hot equipment can cause fires and

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

D Wearers of Pacemakers and other Implante

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their docto

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

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise level is

high.

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

use or connected for use.

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

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

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

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

p
g

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

D Do not install unit near flammables.

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

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

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

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

extend beyond opposite side of unit.

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

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

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

OVERUSE can cause OVERHEATING

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

starting to weld again.

D Do not block or filter airflow to unit.

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.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jum

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

MOVING PARTS can injure.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

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

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

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

D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

H.F. RADIATION can cause interference.

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.

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.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

D If interference still occurs, the user must take extra measures

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

OM-247 643 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 i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org o r purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

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

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

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

Engineering Documents (phone: [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 ww w. sparky.org).

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

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

1-6. EMF Information

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.

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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, NFP A Standard 51B, from National Fire Protection Association,

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

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [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 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

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

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

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

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

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

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

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

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

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-247 643 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.

fre_som_2011−10

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

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

. Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

2-2. Dang ers relatifs au soudage à l’arc

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

Seul un personnel qualifié est autorisé à installer, faire fonc­tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits inter­nes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties 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 cou p e r o u l e s o l .

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

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

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

MENT si le procédé de soudage le demande.

D Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

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

tions suivantes : risques électriques dans un environnement
humide o u s i l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,

dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée. En outre, ne pas travailler seul !

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 afin de s’assurer

qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.

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.

OM-247 643 Page 5

Il reste une TENSION DC NON NÉGLIGEABLE dans

es

de

n­ur

r

t

ge
es

res

t le

ls
ut
nt

s
s

c
n,
e,

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.

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher à mains nues les parti

chaudes.

D Prévoir une période de refroidissement avant

travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomma

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

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

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

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

approuvé.

D Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, l e s
consommables, les revêtements, les nettoyants et les dégrais­seurs.

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

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

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

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements e t tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

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

Le rayonnement de l’arc du procédé de souda

(ultraviolets et infrarouges) susceptibles de provoquer des brûlu
dans les yeux et sur la peau. Des étincelles sont projetées pendan
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 des vêtements confectionnés avec des matières résistan-

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

OM-247 643 Page 6

génère des rayons visibles et invisibles intens

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés te
que des réservoirs, tambours ou des conduites pe

provoquer leur éclatement. Des étincelles peuve
être projetées de l’arc de soudure. La projection d’étincelles, de
pièces chaudes et des équipements chauds peut provoquer de
incendies et des brûlures. Le contact accidentel de l’électrode ave
des objets métalliques peut provoquer des étincelles, une explosio
un surchauffement ou un incendie. Avant de commencer le soudag
vérifier et s’assurer que l’endroit ne présente pas de danger.

D Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

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

sur des substances inflammables.

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

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

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

D Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

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

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

D Brancher l e c â b l e d e m a s s e sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

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

lées.

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

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

D Porter de s v êtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.

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 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.

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

e

et

la
tte

ûr

de

b-

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 confi-

nés 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 s e 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

endommagée, elle peut exploser. Du fait que 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.

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 Détourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

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

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

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

samment de personnes pour soulever et déplacer les bouteilles.

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

l’équipement connexe et le dépliant P-1 de 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 maintenanc

Risque D’INCENDIE OU
D’EXPLOSION.

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

à proximité de surfaces inflammables.

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

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’assu-

rer 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 d u levage
manuelle de pièces ou équipements lourds.

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

D Les étincelles risquent de causer un incendie − éloigner toute su

stance inflammable.

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.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage

les yeux.

D Affûter l’électrode au tungstène uniquement à

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

LES CHARGES ÉLECTROSTATI -

QUES peuvent endommager les cir-

cuits 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 antista-

tiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.

OM-247 643 Page 7

Les PIÈCES MOBILES peuvent

IE

r

r
e,
té

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 BATTER
peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pou

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

Les PIÈCES MOBILES peuvent
causer des blessures.

D S’abstenir d e t o ucher 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

dépannage, 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’entretien en respectant les manuels d’utilisation, les

normes industrielles et les codes nationaux, d’état et locaux.

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

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

provoquer des interférences avec les équi­pements 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’ap-

pareil.

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.

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.

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

compatible électromagnétiquement.

D Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).

D Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

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

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précéden-

tes, 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.

2-4. Proposition californienne 65 Avertissements

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

OM-247 643 Page 8

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.

2-5. Principales normes de sécurité

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

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

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

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

Engineering Documents (phone: [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

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des 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
câbles d’un côté et à distance de l’opérateur.

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

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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, NFP A Standard 51B, from National Fire Protection Association,

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

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [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 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

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

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

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

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

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauf fage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-247 643 Page 9

OM-247 643 Page 10

SECTION 3 − DEFINITIONS

IP

I

I

U

U

A

3-1. WEEE Label (For Products Sold Within The EU)

3-2. Symbols And Definitions

. Some symbols are found only on CE products.

Do not discard this product with
general waste.

Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec­tion facility.

Contact your local recycling office
or your local distributor for further
information.

A

1

Amperes

Degree Of
Protection

Jog Output Trigger Line Connection

Set Up Sequence Trigger Hold On Trigger Hold Off

Purge Press To S et Start Crater

Time Preflow Time Postflow Time Read Instructions

Increase

Primary Voltage

V

Hz

1

B

Volts Alternating Current

Hertz Program Wire Feed

Primary Current

Dual Schedule

2

Rated Current

X

2

Duty Cycle

Load Voltage

OM-247 643 Page 11

SECTION 4 − INSTALLATION

4-1. Important Information Regarding CE Products (Sold Within The EU)

A. Information On Electromagnetic Fields (EMF)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.

This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.

S The EMF assessment on this equipment was conducted at 0.5 meter .
S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.

ce-emf 1 2010-10

B. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−

voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con­ducted as well as radiated disturbances.

ce-emc 3 2011-09

4-2. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the rear panel. 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.

4-3. Specifications

Type of Input Power

24 Volts AC

Single-Phase

50/60 Hertz

* See Section 4-8 for detailed information on wire type, wire size, and wire feed speed.

Welding Power

Source Type

Constant Voltage (CV)

DC With 14-Pin And

Contactor Control

Wire Feed Speed IP Rating

Standard:

50 To 780 ipm

(1.3 To 19.8 mpm)

IP 2X Length: 17 in.

Overall

Dimensions

(432 mm)

Width: 8.5 in.

(216 mm)

Height: 12 in.

(305 mm)

Weight

30 lb

(13.6 kg)

OM-247 643 Page 12

4-4. Equipment Connection Diagram

1

2

3

4

12

1 Welding Power Source
2 Remote 14 Connection
3 Positive (+) Weld Output

Cable

4 Negative (−) Weld Output

Cable
5 Workpiece
6 Weld Control
7 Boom
8 Gun
9 Swivel
10 Pipe Post And Base
11 Gas Hose
12 Gas Supply and Regulator

(Customer Supplied)

. Shielding gas pressure not to

exceed 100 PSI (689 kPa).

11

6

5

7

10

9

8

252 429-A

OM-247 643 Page 13

4-5. Installing Control Box And Adjusting Tilt

1

2

4

3

Tools Nee d e d :

3/8 in.

1 Weld Control
2 Bracket
3 Screw
Bracket and screws are installed

onto bottom of control at factory.
4 Swivel
Loosen screws. Place control on

5

7

swivel and slide forward. Tighten
screws.

5 Tilt Bracket
6 Rear Pivot Screw

6

7 Front Screw
Loosen rear pivot screw. Remove

front screw. Pivot control down­ward to desired viewing angle. Re­place and tighten front screw. Tight­en pivot screw.

4-6. Control Box Connections

1

Ref. 252 427-A

1 Interconnecting Cables
2 14 Pin Receptacle
3 Power Connector
4 USB Port
5 19 Pin Receptacle

OM-247 643 Page 14

2

3
4

5

Ref. 252 426-A / 252 428-A

4-7. 14-Pin Plug Information For Connecting Wire Feeder To Power Source

Notes

Pin* Pin Information

A 24 volts AC with respect to socket G.
B Contact closure to A completes 24 volts AC contactor control circuit.
G Circuit common for 24 volts AC circuit.
C +10 volts DC input from power source to wire feeder with respect to socket D.

I

G

F

*The remaining pins are not used.

B

L

NH

C

M

D

E

AJ

K

D Remote control circuit common.
E 0 to +10 volts DC output signal from wire feeder to power source with respect to socket D.
H V oltage feedback; 0 to +10 volts DC, 1 volt per 10 arc volts.
F Current feedback; 0 to +10 volts DC, 1 volt per 100 amperes.

L 0 to +10 volts DC output signal from wire feeder to power source with respect to socket N.
M CC/CV select 0 to +10 volts DC.
N Feeder common.
K Not used.

4-8. Wire Type, Size, And Optimal Wire Feed Speed Table

Motor Speed Wire Type Wire Size Rated Speed Range (per IEC 60974-5)

Standard All .035 To .062 in. (0.9 To 1.57 mm) 55 To 770 ipm (1.4 To 17.8 mpm)
Standard All 5/64 in. (2 mm) 55 To 700 ipm (1.4 To 17.8 mpm)

OM-247 643 Page 15

5-1. Power Switch

SECTION 5 − OPERATION

1 Power Switch

5-2. Jog/Purge Switch

1

Ref. 252 426-A

1 Jog/Purge Switch

1

Pressing the Jog/Purge switch allows the op­erator to jog wire without energizing the weld
power or gas valve circuit.

• The unit provides the ability to jog the wire
feeder by means of the gun trigger or the
Jog/Purge switch.

• If the welding arc does not initiate in 3 sec­onds after the gun trigger is activated, the
unit will p e r f o r m a j o g o p e r a t i o n f o r a m a x i -

OM-247 643 Page 16

mum of two minutes. If the gun trigger is still
activated after two minutes, the jog opera­tion is terminated to prevent complete des­pooling o f the wire, in the case of a damaged
gun.

• The unit displays the “TRIG ERR“ message
to inform the operator that the trigger is acti­vated.

• Jog speed can be adjusted by the Adjust

Ref. 252 426-A

control when the unit is jogging wire. The
unit displays jog speed when the unit is be­ing jogged.

• Jogging can also be accomplished by
pressing the Jog/Purge button.

• Pressing the Jog/Purge button also allows
the operator to purge gas lines before weld­ing and to preset gas pressure at the
regulator.

5-3. Front Panel Controls

Notes

2

1

1 Adjust Control Left

(See Section 5-6)
2 Left Display (See Section 5-4)
3 Right Display (See Section 5-5)

7

4 Adjust Control Right

(See Section 5-6)

5 Left/Right Display Push Button

(See Section 5-10)

6 58

3

4

6 Crater Push Button (See Section 5-9)
7 Start Push Button (See Section 5-8)
8 Setup Push Button

(See Section 5-7)

OM-247 643 Page 17

5-4. Left Display

1

3

2

4

5

1 Left Side Schedule A LED
2 Left Side Schedule B LED
3 Left Display
4 Arc Length LED
5 Volts LED

5-5. Right Display

. To set the correct voltage range for a par-

ticular power source, see Section 5-11 −
Power Source Selection Menu.

Left Display

The left display shows voltage or arc length.

3

5

The unit displays both preset and actual arc
voltage. When the unit is in a welding state,
actual arc voltage is displayed.

. See Section 7-2 for selection of arc length

and voltage display.

1

2

1 Right Side Schedule A LED
2 Right Side Schedule B LED
3 Right Display
The right display shows wire feed speed or

amperage. The unit displays and adjusts only
preset wire feed speed at idle. When the unit
is in a welding state, actual wire feed speed is
displayed for the active welding sequence.

4 Wire Feed Speed LED
5 Amps LED
The LEDs below the display illuminate to indi-

OM-247 643 Page 18

cate which value is being shown.

• If the unit is in a welding state that does not
involve feeding wire, the unit displays the
weld sequence wire feed speed. At any time
during welding, the weld sequence wire
feed speed can be adjusted and overrides
the preset wire feed speed display. In other
words, if the Adjust control is activated while
welding, the unit displays and permits ad-

4

justment of the weld sequence wire feed
speed regardless of the active welding se­quence.

• When the unit is displaying amperage, the
Amps LED illuminates. Amperage is only
displayed i f the unit is in a welding state and
the amperage is above a minimum value of
25 Amps.

5-6. Adjust Control Left/Right

1

5-7. Setup Push Button

2

1

1 Adjust Control
Use Adjust control to change vari-

ous parameters or menu items.
Use left control to adjust volts or arc

length.
Use right control to adjust amper-

age or wire feed speed.

1 Setup Push Button
2 Setup LED
When the Setup button is pressed,

the Setup push button LED turns on.
Press button to enter basic setup

features. Hold button to enter more
advanced setup features

5-8. Start Push Button

2

1

5-9. Crater Push Button

2

1

1 Start Push Button
2 Start LED
Press button to activate/deactivate

start parameters. LED is on when
start is enabled. Press and hold but­ton for 1 second to access start para­meter menu.

1 Crater Push Button
2 Crater LED
Press button to activate/deactivate

crater parameters. Press and hold
button for 1 second to access crater
parameter menu.

OM-247 643 Page 19

5-10. Left/Right Display Push Button

2

1

5-11. Power Source Selection Menu

1 Left/Right Display Push Button
2 Left Side Activate LED
3 Right Side Activate LED

3

Press button to activate left or right
side.

1 Left Display
2 Right Display

1

* * Power Source

Invision/XMT 35X MPa
Invision/XMT 45X MPa

Deltaweld 302 DELT 302 Vmin =10 Vmax =32
Deltaweld 452 DELT 452 Vmin =10 Vmax =38
Deltaweld 652 DELT 652 Vmin =10 Vmax =44
Dimension 302 DIM 302 Vmin =10 Vmax =32

Dimension NT 450 DIM 450 Vmin =10 Vmax =38
Dimension 452 DIM 452 Vmin =10 Vmax =38
Dimension 652 DIM 652 Vmin =10 Vmax =65
XMT 304 XMT 304 Vmin =10 Vmax =35
XMT 350 XMT 350 Vmin =10 Vmax =38
XMT 456 XMT 456 Vmin =10 Vmax =38

Invision 456
Invision 354
Optima
Custom

Left Display

MPa 35X Vmin =10 Vmax =38
MPa 45X Vmin =10 Vmax =38

INV
INV 354
OPT IMA
CUST PWR.S

Right Display

456

2

Voltage Range

Vmin =10 Vmax =38
Vmin =10
Vmin =10
Vmin =10 Vmax =38

Vmax =35
Vmax =38

. When the feeder is turned on,

the Power Source Selection
Menu allows the operator to se­lect a default power source.
Selecting a default power
source, automatically sets the
correct Vmin and Vmax set­tings for adjusting the output
voltage of t h e p o w e r source.

First Time Feeder Is T urned On

The feeder automatically goes into
the Power Source Selection Menu.
The feeder displays “MPA” on the
Left Display and “35X” on the Right
Display, meaning that a MPa 350
amp machine is the default power
source, and has a voltage range of
10V as Vmin and 38V as Vmax.

At power up, the operator has three
seconds to select a default power
source from the list shown on the
display. Operator may scroll
through the list of power sources by
using the Adjust control. After se­lecting a power source the operator
has three seconds to change to a
different power source or begin
welding. When turning off the feed­er, the default power source will be
retained.

Next Time Feeder Is T urned On

The feeder will display the last se­lected default power source. The
operator has three seconds to se­lect another power source, or press
the Program Button to exit the Pow­er Source Selection Menu.

** For any power sources not listed, pick a matching voltage range or see

Section 5-6 to set Vmin and Vmax.

OM-247 643 Page 20

5-12. Operational Terms

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

General Terms:
Cold Wire Jog Feeding wire without contactor or gas valve being energized.

Sequence A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.
Weld Program A group of sequences that make up a weld cycle.

MIG CV weld process with individual settings of voltage and wire feed speed.
Pulsed MIG CC weld process with factory taught data using peak and background current, pulse width and pulses

Synergic Refers to the system’s ability to match the power setting to the set wire feed speed using a single

Non- Synergic Refers to independent control of wire feed speed and power output. In non−synergic mode, increasing

STD Basic trigger function, weld sequence starts when the trigger is pressed and ends when the trigger is

Trigger Hold Trigger function allowing the operator to weld without continuously pressing the gun trigger . In Trigger

Spot Trigger function that automatically shuts the weld off after a set amount of time. The weld will end

Arc Length Refers to physical distance between wire electrode and molten puddle. Term also used to represent

Dual Schedule Allows selecting a pair of weld parameter settings that can be used together.
Preflow The amount of time that the shielding gas will flow after the trigger is pressed and before the welding

Postflow The amount of time that the shielding gas will flow after the arc has been shut off.
Start Provides voltage/arc length, wire feed speed and time values for modified arc start.
Profile Pulse Profile Pulse optimizes aluminum weld bead appearance by producing welds with consistently

per second. Adaptive pulse control methods modulate one or more of the taught data parameters to
regulate or maintain a fixed arc length.

knob control. In synergic Pulsed MIG, the pulse parameters are automatically increased or decreased
to match the power output to the set wire feed speed.

or decreasing the set wire feed speed requires corresponding adjustment of the arc length or voltage
setting.

released.

Hold mode, momentarily press the gun trigger until an arc is established, and welding will continue
until the gun trigger is momentarily pressed again.

when the set time has expired or the trigger has been released, which ever occurs first. The spot time
is reset when the trigger is released.

adjustments in the Pulsed MIG weld process.

arc will be allowed to be active.

spaced ripple patterns, similar to GTA W.

OM-247 643 Page 21

SECTION 6 − SETTING SEQUENCE PARAMETERS

6-1. Sequence Parameters In A Program

Sequence Parameters

Volts IPM Seconds

1. Preflow 0.0-30.0

2. Run-In

3. Start .1-.5XX

4. Weld

5. Crater

6. Postflow

XX
XX

X x0.1-x1.00

0-100.0

0.00-5.00

0.0-30.0

Preflow

Trigger

Pressed

X = Setting available.

Preflow

Time

Start

Start
Time

Weld Time

Crater

Time

Postflow

Time

Time

WeldRun-In

Trigger

Released

PostflowCrater

Sequence

End

OM-247 643 Page 22

7-1. Setup Menu

Notes

SECTION 7 − PROGRAMMING

To enter the SETUP MENU press and re­lease the SETUP button. The SETUP

MENU INDICATOR and the SETUP
BUTTON INDICATOR will illuminate.

Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT

DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown

in the RIGHT DISPLAY.
To exit the SETUP MENU press and re-

lease the SETUP button.
Items that can be adjusted in this menu are:
Trigger Control (TRIG) − Sets the gun

trigger control. The trigger control can be
configured as (STD, HOLD, or SPOT).

Trigger Hold Delay (HOLD) − Additional
trigger setting only appearing in the menu
when the trigger control is set to (TRIG
HOLD). T rigger hold delay time is the min­imum amount of time the trigger must be
held for trigger hold to become active.
There is a built in maximum trigger hold
time which the trigger must be released

within for trigger hold to become active.
The maximum trigger hold time is always

4.0 seconds after the trigger hold delay
time. For Example, if the trigger hold delay
time is set to 2.0 seconds, the trigger must
be held for at least 2.0 seconds and re­leased within 6.0 seconds for trigger hold to
become active. Once the trigger hold func­tion is active, the wire feeder will continue
feeding wire until the trigger is pressed and
released again.

Trigger Spot Time (SPOT) − Additional
trigger setting only appearing in the menu
when the trigger control is set to (TRIG
SPOT). The SPOT time is the length of
combined time for the start (if applicable)
and the weld sequence. The weld will end
when the set time has expired or the trigger
has been released, whichever occurs first.
The spot time is reset when the trigger is re­leased.

Preflow (PRE) − The amount of time that
the shielding gas will flow after the trigger
is pressed and before the welding arc will

be allowed to be active. Range of this set­ting is from (0.0 to 5.0) seconds.

Postflow (POST) − The amount of time
that the shielding gas will flow after the arc
has been shut off. Range of this setting is
from (0.0 to 10.0) seconds.

Run−In Speed (R−IN) − The wire feed
speed prior to the welding arc being struck.
This setting is a percentage of the wire feed
speed the unit is set to for welding. Range
of this setting is from (X0.10 to X0.99 to
OFF). Example: If the weld wire speed is
200 and R−IN is X0.50, the run−in wire
speed is 100.

Profile Pulse ON/OFF − When Profile
Pulse is On, the pulse parameters and wire
speed are coordinated to produce a con­sistent ripple pattern.

. Additional PROFILE PULSE menu

items may appear in the SETUP
MENU when PROFILE PULSE is act-

ive. See Section 7-5.

OM-247 643 Page 23

7-2. Setup Menu Level 2

T o enter the SETUP MENU LEVEL 2 press
and hold the SETUP button. The SETUP

MENU INDICATOR and the SETUP
BUTTON INDICATOR will illuminate.

Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT

DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown

in the RIGHT DISPLAY.
To exit the SETUP MENU LEVEL 2 press

and release the SETUP button.
Items that can be adjusted in this menu are:
Parameter Lock (LOCK) − When set to

(ON), the Preflow, Postflow, Run−In, Start,
and Crater parameters are locked and can­not be adjusted. Attempting to change a
locked parameter causes the display to mo­mentarily display (LOCK).

Range Limits (LMTS) − When set to (ON),
the wire feed speed and arc length or
voltage weld settings are limited to minim­um and maximum adjustable ranges. The
minimum and maximum range settings ap­pear next in the menu when (LMTS) is set
to (ON). When set to (OFF), range limits are
inactive and do not appear in the menu.

Wire Feed Range Limit (MIN) − Indicated
in the LEFT DISPLAY with the WIREFEED
SPEED INDICATOR illuminated. Sets the
minimum wire feed speed. Range of this
setting is from 50 to 780 IPM.

Wire feed Range Limit (MAX) − Indicated
in the LEFT DISPLAY with the WIREFEED
SPEED INDICATOR illuminated. Sets the
maximum wire feed speed. Range of this
setting is from (MIN) setting to 780 IPM.

Arc Length Range Limit (MIN) − Indicated
in the LEFT DISPLAY with the ARC
LENGTH INDICATOR illuminated. Sets the
minimum arc length. Range of this setting is
from 0 to 100.

Arc Length Range Limit (MAX) − Indic­ated in the LEFT DISPLAY with the ARC
LENGTH INDICATOR illuminated. Sets the

maximum arc length. Range of this setting
is from (MIN) setting to 100.

. When the DISP option in the SETUP

MENU LEVEL 2 is set to (VOLT), the
Arc Length Range Limits are replaced
by Voltage Range Limits.

Voltage Range Limit (MIN) − Indicated in
the LEFT DISPLAY with the VOLTS
INDICATOR illuminated. Sets the minimum
voltage. Range of this setting is dependent
on the power source voltage range in the
MIG process.

Voltage Range Limit (MAX) − Indicated in
the LEFT DISPLAY with the VOLTS
INDICATOR illuminated. Sets the minimum
voltage. Range of this setting is dependent
on the power source voltage range in the
MIG process.

Display (PULS) − Allows the preset weld
parameter adjustment to be set as voltage
or arc length. This setting effects only the
display appearance and will not effect oper­ation. The (PULS) setting should be set to
match the power source display. When set
to (VOLT), the preset voltage set point will
be shown in the Left Display with the
VOLTS INDICATOR illuminated. When set
to (ARC.L), the preset arc length will be
shown in the Left Display with the ARC
LENGTH INDICATOR illuminated.

Trigger Schedule Select (SCHD) − Allows
the operator to select the alternative sched­ule by quickly tapping the gun trigger when
not welding. When set to (OFF), trigger
schedule select is disabled. When set to
(TRIG), the schedule is selected by tapping
the gun trigger when not welding. The
pulling and release of the gun trigger must
happen within 0.2 seconds for the schedule
to change.

Menu Lock Code (CODE) − Allows setting
a numerical password code to obstruct ac­cess to the Setup Menu Level 2. By default,
(CODE) is (OFF) allowing access to the
menu without entering a password. The
password can be programmed to values
between 0 and 999. Once programmed, the

password must be re−entered each time
the menu is accessed. A failed password
attempt causes the display to momentarily
show (CODE FAIL). (CODE) will continue
to show on the display until the correct
password is entered or the power is cycled.

. Anytime the menu is exited with

(CODE OFF), a special sequence is
required before a new password can
be set. With (CODE OFF) shown on
the display, press and hold the SETUP
button and rotate the RIGHT ADJUST
KNOB to set the password to (0123).
Release the SETUP button, the display
should read (CODE 0000). The pass­word can now be set to a new value.

Weld Time − This setting displays weld
time for each feeder side. You can scroll
through the menu by rotating the right knob
in the menu. Left side time, right side time
then total time are displayed sequentially.

Weld Runs − This setting displays weld
cycles for each feeder side. You can scroll
through the menu by rotating the right knob
in the menu. Left side cycles, right side
cycles then total weld cycles are displayed
sequentially.

Life Zero − This setting will erase left and
right weld time and weld cycles. Total time
and total cycles are not reset. Time reset is
initialized by rotating the right knob which
initiates a second counter. When “Life
Done” is displayed you must exit the menu
by pressing the setup button. The 5 second
counter can be reset by rotating the right
knob back before “Life Done” is displayed.

Power Source Menu (P.MEN) − This set­ting turns the power on power source menu
“ON” or “OFF” at power up.

Product Version Information (INFO) −

Provides information about the firmware re­vision levels for the Motor Control and the
User Interface PCBs The default value is
(INFO NONE). To read the firmware ver­sions rotate the Right Adjust Knob until the
display reads (INFO MOTR) or (INFO
FRNT). The corresponding firmware revi­sion level will momentarily appear following
a short delay.

OM-247 643 Page 24

7-3. Setting A Start Sequence

To turn on a Start sequence, press the

START button. The START ON
INDICATOR will illuminate indicating Start

is active.
To turn off the Start sequence, press the

START button. The START ON
INDICATOR will turn off indicating Start is

inactive.

. The factory default mode for Start is

(DFLT). The (DFLT) setting has preset

parameters. Start can also be set to

(MAN) for manual settings. The Start

mode can be changed in the START

MENU.

. Following are START (DFLT) paramet-

ers for the active schedule.

To enter the START MENU press and hold
the START button until the START MENU
INDICATOR illuminates.

Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT

DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown

in the RIGHT DISPLAY.
To exit the START MENU, press and re-

lease the START button.
Items that can be adjusted in this menu are:
Start Wire Feed Speed (WFS) − Sets the

wire feed speed used during the Start T ime.
This setting is a percentage of the wire feed
speed the unit is set to for welding. Range
of this setting is from (X0.5 to X2.50).
Example: I f the weld wire feed speed is 200
and WFS is X1.50, the Start Wire Feed
Speed is 3 0 0 .

Start Arc Length (ARC.L) − Sets the arc
length longer or shorter during the Start
Time. This setting is a percentage of the arc
length the unit is set to for welding. Range
of this setting is from (X0.50 to X1.50).
Example: If the weld arc length is set to 50
and ARC.L is X0.50, the Start Arc Length is

25.

. When the DISP option in the SETUP

MENU LEVEL 2 is set to VOLT, the

Start Arc length setting will be replaced
by the Start Voltage (VOLT) setting.

Start Voltage (VOLT) − Sets the voltage
during the Start Time. Range of this setting
is dependent on the power source voltage
range in the MIG process, and varies with
the selected wire and gas program in the
PULSED MI G process. If the power source
weld process is set to PULSED MIG, the
Start Voltage setting will change if the wire
and gas program selection is changed.

Start T ime (TIME) − The amount of time the
wire feed speed is active at the Start setting.
Range of this setting is from (0.1 to 0.5)
seconds.

Start Ramp T ime (RAMP) − The amount of
time it takes to transition from the Start to
the weld wire feed speed setting. Range of
this setting is from (0.1 to 5.0) seconds.

OM-247 643 Page 25

7-4. Setting A Crater Fill Sequence

To turn on Crater Fill, press the CRATER
button. The CRATER ON INDICATOR will
illuminate indicating Crater Fill is active.

To turn off Crater Fill, press the CRATER
button. The CRATER ON INDICATOR will
turn off indicating Crater Fill is inactive.

. The factory default mode for Crater Fill

is (DFLT). The (DFLT) setting has pre­set parameters. Crater Fill can also be
set to (MAN) for manual settings. The
Crater mode setting can be changed in
the CRATER MENU.

. The Crater Tack Time (TACK) is ad-

justable in both AUTO and MAN
modes.

To enter the CRATER MENU press and
hold the CRATER button until the CRATER
MENU INDICATOR illuminates.

Rotate the LEFT ADJUST KNOB to select
different menu items shown in the LEFT

DISPLAY. Rotate the RIGHT ADJUST
KNOB to change menu item values shown

in the RIGHT DISPLAY.

To exit the CRATER MENU press and re­lease the CRATER button.

Items that can be adjusted in this menu are:
Crater Wire Feed Speed (WFS) − Sets the

Crater Fill wire feed speed. This setting is a
percentage of the wire feed speed the unit
is set to for welding. Range of this setting is
from (X0.30 to X1.00). Example: If the weld
wire feed speed is 200 and WFS is X0.50,
the Crater wire feed speed is 100.

Crater Arc Length (ARC.L) − Sets the arc
length longer or shorter during the Crater
Fill T ime. This setting is a percentage of the
arc length the unit is set to for welding.
Range of this setting is from (X0.50 to
X1.50). Example: If the weld arc length is
set to 50 and ARC.L is X0.50, the Crater Arc
Length i s 2 5 .

. When the DISP option in the SETUP

MENU LEVEL 2 is set to VOLT, the

Crater Arc Length setting will be re­placed by the Crater Voltage (VOLT)
setting.

Crater Voltage (VOLT) − Sets the voltage
during t h e Crater Fill time. Range of this set-

ting is dependent on the power source in the
MIG process, and varies with the selected
wire and gas program in the PULSED MIG
process. If the power source weld process
is set to PULSED MIG, the Crater Voltage
setting will change if the wire and gas pro­gram selection is changed.

Crater Ramp Time (RAMP) − The amount
of time it takes to transition from the weld to
the Crater wire feed speed setting. Range
of this setting is from (0.1 to 5.0) seconds.

Crater Fill Time (TIME) − The amount of
time the wire feed speed is active at the
Crater setting. Range of this setting is from
(0.1 to 5.0) seconds.

Crater Tack Time (TACK) − This setting is
for tack welding without crater fill. The
Crater fill will not be active if the arc time is
less than the set time. Range of this setting
is from (0.1 to 5.0) seconds.

Crater Factory Default (DFLT) − To reset
crater to factory default settings select
(DFLT). Range of this setting is from (5 to 0)
seconds.

OM-247 643 Page 26

7-5. Profile Pulse

Profile Pulse optimizes Aluminum weld
bead appearance by producing welds with
consistently spaced ripple patterns, similar
to GTAW. This feature has been designed
to operate in a Synergic Pulsed MIG sys­tem. The consistent ripple pattern is
achieved b y periodically changing both the
wire feed speed and power level. The aver­age wire feed speed is determined by the
value the unit is set to for welding.

Profile Pulse Items that can be adjusted in
the Setup Menu are:

Profile Pulse ON/OFF (PROF) − Allows
Profile Pulse to be turned on or off.

Profile Pulse Frequency (P.FRQ) − Sets
the spacing between ripples in the weld
bead. Range of this setting is from (0.1 to

5.0) pulses per second. See Figures 1 and
2 below.

Profile Pulse Wire Feed Speed Change
(P.WFS) − Sets the percentage of change

above and below the wire feed speed the
unit is set to for welding. Range of this set­ting is (X0.00 to X0.30). Example: If the wire

feed speed is 200 and (P.WFS) is set to
(X0.10), the wire feed speed will alternate
between 180 and 220 ipm.

Profile Pulse Arc Length (P.AL) − Sets an
arc length correction factor for the lower
wire feed speed. This setting is a percent­age of the arc length the unit is set to for
welding. Range of this setting is from (X0.5
to X1.5). Example: If the arc length for weld­ing is set to 50 and (P.AL) is set to (X1.1),
the arc length setting for the lower wire feed
speed is 55 .

Constant travel speed with P.FRQ set to 0.1

Constant travel speed with P.FRQ set to 5.0

Figure 1

Figure 2

OM-247 643 Page 27

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

! Disconnect power before maintaining.

n = Check ~ = Clean l = Replace

Every
Spool
of Wire
or Wire
Change

n~ Gun Liner

Every
3
Months

l Unreadable Labels ~ Weld T erminals nl Weld Cable l Cracked Parts

n 14-Pin Cord n Gas Hose and Fittings n Gun Cable

Every
6
Months

~ Inside Unit ~ Drive Rolls

Or

8-2. Diagnostics

The following error messages are shown on the displays to indicate specific errors. Explanations are in the text below:

TRIG ERR Indicates a trigger error. A trigger error occurs if the user has the trigger held for more than two

JOG ERR Indicates a jog switch error. A jog switch error occurs if the user has the jog switch held for more than

PURG ERR Indicates a purge switch error. A purge switch error occurs if the user has the purge switch held for

COOL ERR Indicates a water flow switch error. A water flow switch error occurs if no water flow is detected while

TEST ERR.1 or

ERR.2

COMM ERR Indicates a serial communication error. A communication error occurs 2 seconds after a loss of com-

1234 ERR.M Indicates a motor control pcb error. If this error occurs, contact a Factory Authorized Service Agent.
1234 ERR.F Indicates a front panel pcb error. If this error occurs, contact a Factory Authorized Service Agent.
R.Tac ERR Indicates the right push motor tachometer circuit has an error.
L.Tac ERR Indicates the left push motor tachometer circuit has an error.
G.Tac ERR Indicates tachometer in push-pull gun has an error.

minutes without striking an arc. This error also occurs if the trigger is held when the feeder is powered
up. The error may be cleared by releasing the trigger.

two minutes. This error also occurs if the jog switch is held when the feeder is powered up. The error
may be cleared by releasing the jog switch.

more than one minute. This error also occurs if the purge switch is held when the feeder is powered
up. The error may be cleared by releasing the purge switch.

the trigger is pressed. Jog and purge switches will behave normally even if no water flow is detected.
Dip switch 2 on the motor control pcb must be set to enable this error. The error is cleared when wa­ter flow is detected or when the error is disabled.

Indicates a power on self diagnostic test error. The number provides information regarding the error.
If this error occurs, contact a Factory Authorized Service Agent.

munication between the motor control pcb and the front panel pcb.

OM-247 643 Page 28

8-3. Troubleshooting

! Disconnect power before troubleshooting.

t

Trouble Remedy

Pressing gun trigger does not energize
feeder. Shielding gas does not flow and
wire feeder does not feed.

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

Wire feeds erratically.

Arc varies and welding wire is kinked
when feeding out gun.

No weld output; gun/feeder does not
work.

Erratic weld output.

Secure plug from gun control cable into Gun Control receptacle.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
Check to see if ground clamp or weld cable is connected.

Verify proper wire size is selected (see Section 7-2).
Check drive roll pressure in wire feeder and gun.
Clean or replace drive rolls as necessary.
Check and replace liner if necessary.
Verify proper wire size is selected (see Section 7-2).

Check gun control cable connection.

Tighten and clean all connections.
Replace contact tip.
Verify proper wire size is selected (see Section 7-2).
Check drive roll pressure in wire feeder and gun.
Check and replace liner if necessary.
When welding aluminum, it is important to use minimal drive roll pressure and minimal brake tension to

achieve consistent wire feeding.

Wire does not feed; burnback in contac
tip.

Gun overheating
(water-cooled models).

Motor does not run.

Verify drive roll size is correct.
Check drive roll pressure in wire feeder and gun.
Check and replace liner if necessary.
Be sure coolant flow rate is at least 1 qt/min.
Corrosion buildup in gun decreasing coolant flow rate. Backflush coolant system, clean coolant system

filter, and clean fittings.
Check drive roll pressure in wire feeder and gun.
Check and replace liner if necessary.
Have Factory Authorized Service Agent check feeder.

OM-247 643 Page 29

SECTION 9 − ELECTRICAL DIAGRAM

OM-247 643 Page 30

Figure 9-1. Circuit Diagram

OM-247 643 Page 31

247 591-A

SECTION 10 − PARTS LIST

25

27

26

6

7

12

7

14

15

. Hardware is common and

not available unless listed.

12

13

5

2

1

18

4

16

17

19

22

21

28

20

29

3

30

16

9

8

11

10

24

23

Figure 10-1. D-74 MPa Plus Control Box

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 10-1. D-74 MPa Plus Control Box

1 +207 496 Wrapper, Feeder 1... .............. .. ...............................................

2 238 487 Label, Warning General Precautionary (CE/Domestic) 1... ............... .. ..............

3 PC1 242 217 Circuit Card Assy, Motor Control W/Prgm 1... .... ..... .. .........................

4 PC3 248 313 Circuit Card Assy, Push-Pull Interface 1... .... ..... .. ............................

5 PC5 244 200 Circuit Card Assy,14 Pin Filter 1... .... ..... .. ...................................

6 244 581 Cable, Power D-74 MPa Plus (Includes) 1... ............... .. ..........................

7 139 041 Strain Relief 1... ............... .... .................................................

8 163 520 Cable, Port 15.0 Ft... ............... .... .............................................

9 079 739 Conn, Circ Cpc Clamp Str Rlf 1... ............... .... ..................................

10 PLG12 141 162 Housing Plug+Pins, (Service Kit) 1... ... .... .... ...............................

PLG30 115 092 Housing Plug Pins+Skts, (Service Kit) 1......... .... .... ..........................

11 244 618 Cover, Connector USB W/Tether 1... ............... .. .................................

12 244 191 Circuit Card Assy, USB Filter 1... ............... .. ....................................

13 251 547 Label, Nameplate Rear 1... ............... .. .........................................

14 249 631 Panel, Rear Control Box 1... ............... .. ........................................

15 PC31 232 880 Circuit Card Assy, 14 Pin Filter HF 1... .... ..... .. ...............................

16 246 559 Strap, Grounding 3.50 In. Long 2... ............... .. ..................................

17 243 080 Enclosure, Feeder 1... ............... .. .............................................

18 134 201 Stand-off Support, PC Card .312/.375w/Post&Lock .43 6... ............... .. ..............

252 430-B

OM-247 643 Page 32

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 10-1. D-74 MPa Plus Control Box (Continued)

19 207 540 Bracket, Mtg Control Box D-74 Swingarc 1... ............... .. ..........................

20 243 078 Panel, Front Feeder 1... ............... .. ............................................

21 000 527 Blank, Snap-in Nyl .875 Mtg Hole Black 2... ............... .. ...........................

22 241 416 Blank, Snap-in Nyl 1.187 Mtg Hole Black 1... ............... .. ..........................

23 251 247 Label, Nameplate D-74 MPa Plus Boom Ctrl Box Lower 1... ............... .. .............

24 S2 200 295 Switch, Rocker Spdt 15A 12V (On)−Off−(On) 1... ..... ...... .. ......................

25 245 663 Knob, Encoder 1.250 Dia X .250 Id Push On W/Spring 2... ............... .. .............

26 231 469 Nut, 500-28 .69Hex .28H Brs Conical Knurl 2... ............... .. ........................

27 Nameplate, D-74 MPa Plus Upper (order by model and serial number) 1... ..........................

28 231 470 Nut, Adapter Encoder Shaft Mtg 375-32 To 500-28 2... ............... .. .................

29 PC2 242 228 Circuit Card Assy, User Interface W/Prgm D-74 MPa 1... .... ..... .. ...............

30 S1 111 997 Switch, Rocker SPST 10A 250VAC On-off Visi Red Rock 1... ..... ...... .. ...........

+When Ordering A Component Originally Displaying A Precautionary Label, The Label Should Also Be Ordered.

To Maintain The Factory Original Performance Of Your Equipment, Use Only Manufacturer’S Suggested
Replacement Parts. Model And Serial Number Required When Ordering Parts From Your Local Distributor.

Dia.

Mkgs.

Part

No.

Description

Quantity

Harness Connectors/Receptacles

Plg1 203 800 Housing Plug+Skts, (Service Kit) 1............ ....... ... .............................

Plg2,6 115 093 Housing Plug+Skts, (Service Kit) 1........... ...... ... .............................

Plg3 115 092 Housing Plug+Skts, (Service Kit) 1............ ....... ... .............................

Plg4,33 130 203 Housing Plug+Skts, (Service Kit) 1.......... ..... ... .............................

Plg5,32 202 592 Housing Plug+Skts, (Service Kit) 1.......... ..... ... .............................

Plg6 115 094 Housing Plug+Skts, (Service Kit) 1............ ....... ... .............................

Plg8,12 136 810 Housing Plug+Skts, (Service Kit) 1.......... ..... ... .............................

Plg10,30 115 091 Housing Plug+Skts, (Service Kit) 1.......... ..... ... .............................

Plg31 130 204 Housing Plug+Skts, (Service Kit) 1........... ...... ... .............................

OM-247 643 Page 33

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)

18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)

1/8 in. (.125 in.)

3/16 in. (.188 in.)

1/4 in. (.25 in.)

5/16 in. (.313 in.)

3/8 in. (.375 in.)

1/2 in. (.5 in.)

Warranty Questions?

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

Y our distributor also gives
you ...

Service

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

Support

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

Effective January 1, 2012

(Equipment with a serial number preface of MC 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.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to an
International distributor.

1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor
* Engine Driven Welding 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
* Smith 30 Series Flowgauge and Flowmeter

Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)

3. 2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted

Separately by the M a n u f a c t u r e r.)

* Load Banks
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

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

guarantees or warranties expressed or implied.

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) Guns
* 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 a n 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 repa ir or r epl ac eme nt w il l 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 2012-01

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

International Headquarters−U SA

USA Phone: [phone] Auto-A t t ended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2012 Miller Electric Mfg. Co. 2012−01

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.