Miller Electric Auto-Axcess 450 User Manual

OM-210 540S 2007−10

Processes

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

Description

Automatic Welding Interface And
Arc Welding Power Source

™

Auto-Axcess 450

Visit our website at

www.MillerWelds.com/ams

File: Advanced Manufacturing Systems

From Miller to You

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

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

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

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

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

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

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

Working as hard as you do

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

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

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

Mil_Thank 4/05

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

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

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

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

7-3. Removing Cover and Measuring Input Capacitor Voltage 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Process Control Module PC4 Diagnostic LED’s 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Diagnostic LED’s On Process Control Module PC4 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Diagnostic LED’s On Wire Feed Module PC6 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. User Interface Module PC7 Diagnostic LED’s 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Diagnostic LED’s On User Interface Module PC7 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Automation Interface Module PC9 Diagnostic LED’s 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11. Diagnostic LED’s On Automation Interface Module PC9 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12. Network And Module Status LED’s 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13. Troubleshooting 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAMS 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

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

1-1. Symbol Usage

som _2007−04

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

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

NOTICE − Indicates statements not related to personal injury .

1-2. Arc Welding Hazards

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

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input

live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch live electrical parts.
D Wear dry , hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats

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

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

there is a danger of falling.

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

unit.

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

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a 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 and ground this equipment according to its

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

power circuit and machine internal circuits are also

. 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.

SIGNIFICANT DC VOLTAGE exists in inverter-type
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 cause severe burns.

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

torch.

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

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

OM-210 540 Page 1

FUMES AND GASES can be hazardous.

d

r
t

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

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

arc to remove welding fumes and gases.

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.

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 fil-

ter lenses to protect your face and eyes 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 mate-

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

WELDING can cause fire or explosion.

D Do not use welder to thaw frozen pipes.
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 of f shielding gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

MAGNETIC FIELDS 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.

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 closed containers such as tanks, drums, or pipes,

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

OM-210 540 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully .

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 shielding gas cylinders, regulators, hoses, and fit-

tings 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

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 UNIT can cause injury.

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.

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 cause injury.

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.

MOVING PARTS can cause injury.

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 as necessary.

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

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read Owner’s Manual before using or servic-

ing unit.

D Use only genuine replacement parts from the

manufacturer.

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.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

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

rolls.

WELDING WIRE can cause injury.

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.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

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

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

OM-210 540 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.)

Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

1-5. Principal Safety Standards

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly , V A 20151 (phone: [phone], website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

Ontario, Canada L4W 5NS (phone: [phone] or in Toronto
416-747-4044, 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 10036–8002 (phone:
212-642-4900, website: www.ansi.org).

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

P.O. Box 9101, Quincy, M A 02269-9101 (phone: [phone], web­site: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

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

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

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

4. Keep welding power source and cables as far away from opera­tor as practical.

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

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-210 540 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

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

2-1. Symboles utilisés

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

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les 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

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

sous tension lorsque le courant est délivré à la

(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 Installer le poste correctement et le mettre à la terre convenable-

ment selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.

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 l a 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.

fre_som_2007−04

OM-210 540 Page 5

Il reste une TENSION DC NON NÉGLIGEABLE dans

es

de

n­ur

tre

r

t

ge
es

res

t le

in-

els
eu
en

es
e

ets

uf-

e

les sources de soudage onduleur quand on a
coupé l’alimentation.

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.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

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 ê
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’intér ieur, ventiler la zone et/ou utiliser une v entilation for cée 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 pendant le soudage
(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-210 540 Page 6

génère des rayons visibles et invisibles intens

LE SOUDAGE peut provoquer un
cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés t
que des réservoirs, tambours ou des conduites p

provoquer leur éclatement. Des étincelles peuv
être projetées de l’arc de soudure. La projection d’étincelles, des pièc
chaudes et des équipements chauds peut provoquer des incendies
des brûlures. Le contact accidentel de l’électrode avec des obj
métalliques peut provoquer des étincelles, une explosion, un surcha
fement ou un incendie. Avant de commencer le soudage, vérifier
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 (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

v­on
du

b-

risquent de provoquer des blessures
ou même la mort.

D Fermer l’alimentation du gaz protecteur 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 MAGNETIQUES peuv­ent affecter des implants médicaux.

D Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

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

avant de s’approcher des opérations de soudage à l’arc, de sou­dage par points, de gougeage, du coupage plasma ou de chauf­fage par induction.

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.

Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma­gée, elle peut exploser. Du fait que les bouteilles de

dage, les manipuler avec précaution.

gaz font normalement partie du procédé de sou-

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 protecteur, 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’APPAREIL peut
blesser.

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.

L’EMPLOI EXCESSIF peut SUR­CHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; re-

specter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

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

stance inflammable.

LES ÉTINCELLES VOLANTES ris­quent de 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. Cette manœu
re est à exécuter dans un endroit sûr lorsque l’
porte l’équipement homologué de protection
visage, des mains et du corps.

LES CHARGES ÉLECTROSTATI ­QUES peuvent endommager les
circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistati-

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

DES ORGANES MOBILES peuvent
provoquer 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.

OM-210 540 Page 7

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 per-

sonnes ou toute pièce mécanique en enga­geant l e fil de soudage.

DES ORGANES MOBILES peuvent
provoquer des blessures.

D S’abstenir d e t o ucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protec­tion.

D Seules des personnes qualifiées sont autorisées à enlever les

portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.

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 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

D N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

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 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.

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

D L’énergie électromagnétique risque de provo-

quer 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)

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi­ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipu­lation.

Pour les moteurs à essence :

Pour les moteurs diesel :

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

OM-210 540 Page 8

2-5. Principales normes de sécurité

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone :
1-877-413-5184, site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor , Chan­tilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de sou­dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir exa­miné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnéti­ques pendant le soudage ou le coupage.

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

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).

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

11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).

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

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www .nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin­tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho­ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).

1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.

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

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

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

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

En ce qui concerne les implants médicaux :

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

OM-210 540 Page 9

OM-210 540 Page 10

SECTION 3 − INSTALLATION

Welding

Speed

Diameter

Circuit

Power

Welding

Range

Speed

Diameter

Circuit

kVA

KW

22-1/2 in

A

22-1/2 in

17-3/32 in

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

3-1. Specifications

Max

Input

Three

Phase

*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.

Rated

Output

450 A @
44 V DC,

100%

Duty

Cycle

Voltage

10-44 Standard:

Wire Feed

Range**

50-1400

ipm

(1.3-35.6

mpm)

Wire

Range

.035-.062 in

(0.8-1.6 mm)

Open

Voltage

DC

80 67.0

Amperes Input At Rated Load Output 60 Hz,

208 V 230 V 400V 460 V 575 V

(0-1A*)

59.0

(0-1A*)

Three-Phase

34.0

(0-1A*)

29.0

(0-1A*)

23.0

(0-1A*)

3-2. Dimensions And Weight

Hole Layout Dimensions

A 17-3/32 in (434 mm)

B 17-3/8 in (441 mm)

C 19-3/32 in (485 mm)

E

(572 mm)

Input

23.8

(0.8*)

Input

22.9

(0.17*)

31 in

(787 mm)

D 16-3/32 in (409 mm)

E 1/2 in (13 mm)

Weight

163 lb (74 kg) Net

180 lb (82 kg) Ship

B

C

(434 mm)

D

Ref. 803 244-B

OM-210 540 Page 11

3-3. Duty Cycle And Overheating

3-4. Volt-Ampere Curves

100% Duty Cycle At 450 Amperes 60% Duty Cycle At 580 Amperes

Duty Cycle is percentage of 10 mi n ­utes that unit can weld at rated load
without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Continuous Welding

Overheating

80

70

60

50

40

VOLTAGE

30

CV MODE

0

Minutes

6 Minutes Welding 4 Minutes Resting

A/V

15

OR

Reduce Duty Cycle

duty1 4/95 − 220 485-A

Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
between curves shown.

. This volt-ampere curve

represents the dynamic output
of the unit with a static load.

20

10

0

0 100 200 300 40 0 500 600 700

AMPERA GE

OM-210 540 Page 12

va_curve1 4/95 − 220 486-A

3-5. Selecting A Location

Movement

Location

Tipping

2

OR

1

! Do not move or operate

unit where it could tip.

! Do not stack units. Beware of

! Special installation may be required where gasoline or volatile

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

4

3

18 in

(460 mm)

18 in

(460 mm)

tipping.

1 Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side

of unit.
2 Hand Cart
Use cart or similar device to move

unit.
3 Rating Label
Use rating label to determine input

power needs.
4 Line Disconnect Device
Locate unit near correct input

power supply.

3-6. Connection Diagram

2 3

1

12

10

11

loc_2 3/96 -Ref. 803 244-B

. The proper interface kit must

be installed in the welding

5

4

6

7

8

power source/interface unit to
allow it to be connected to the
robot.

1 Robot (Will Vary According To

Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
6 Robot Input/Output Cable
7 Gas And Motor Control Cable
8 Welding Power

Source/Interface Unit
9 Negative (−) Weld Cable
10 Workpiece
11 Voltage Sensing Lead
Recommended for Accu-pulse and

RMD (optional).

. Positive (+) voltage sensing

lead is contained in the motor

cable.

12 Positive (+) Weld Cable

9

Ref. 803 244-B / Ref. 801 915-A

OM-210 540 Page 13

3-7. Rear Panel Receptacles And Supplementary Protectors

4

5

2

3

6

1

1 115 V 10 A AC Receptacle RC2
Receptacle supplies 60 Hz

single-phase power. Maximum output
from RC2 is limited by supplementary
protector CB1 to 10 amps.

2 Supplementary Protector CB1
3 Supplementary Protector CB2
CB1 protects 115 volt receptacle RC2

from ov e r l oad. If CB1 opens, RC2 does
not work.

CB2 protects the wirefeed motor from
overload. If CB2 opens, the wirefeeder
does not work.

. Press button to reset breaker. If

breaker continue to open, contact a
Factory Authorized Service Agent.

4 Wirefeed/Gas Receptacle RC8
Use receptacle to connect gas and

motor control cable to power source
(see Sections 3-6 and 8 for additional
information).

5 Peripheral Receptacle RC25
Receptacle provides connection to

touch sensor, water flow switch, jog +/−,
and I/O relay contacts circuitry (see
Section 3-10).

6 Robot Interface Receptacle RC72
Use receptacle to connect robot

input/output cable (see Sections 3-6
and 8 for additional information).

Ref. 803 245-B

OM-210 540 Page 14

3-8. Connecting To Weld Terminals

. If using an electrode negative (straight polarity)

process, the volt sense lead must be connected
to the work.

1

3

4

5

Tools Needed:

3/4 in (19mm)

! Turn off power before connecting to

weld output terminals.

! Failure to properly connect weld

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

Determine total cable length in weld circuit
(both positive and negative cables
combined) and maximum welding
amperes. S e e Section 3-9 to select proper

6

Do not place

anything between

weld cable terminal

and copper bar.

Correct Installation

cable size.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Connect positive weld cable to Positive (+)

weld terminal and negative (−) cable to
Negative weld terminal.

3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal

2

Incorrect Installation

Ref. 803 244-B / 803 778-A

6 Copper Bar

Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
weld output terminal and secure with nut so
that weld cable terminal is tight against
copper bar. Do not place anything

between weld cable terminal and copper
bar. Make sure that the surfaces of the
weld cable terminal and copper bar are
clean.

OM-210 540 Page 15

3-9. Selecting Weld Cable Sizes*

Positive Negative

Positive

Negative

! ARC WELDING can cause Electromagnetic Interference.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.

100 ft (30 m) or Less

Weld Output

Terminals

! Turn off power before

connecting to weld
output terminals.

! Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes**

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

10 − 60%

Duty

Cycle

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

Not Exceeding****

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105

m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

400 ft

(120

m)

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

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

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

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

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

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

600 3/0 (95) 4/0 (120)

)

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

**Cable should be sized for Peak Amperage (Apk) for pulse welding applications.
***Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm2 for metric use
****For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. S-0007-E

*

Ref. 803 246-B

700 4/0 (120)

800 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

4/0

(120)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

4 ea. 4/0

(4x120)

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

characteristics with undersized cables. A recommendation for weld cable size is a minimum of 2/0 for 300 ampere welding power sources and
4/0 for 450 ampere welding power sources when total cable length is less than 100 ft (30m).

OM-210 540 Page 16

3-10. Peripheral Receptacle Functions

C

K

F

Signal

l

And Output Signal

B

D

E

A

L

M

J

H

Coolant Flow

Switch Input

Function Socket Socket Information

A Not used.

B Not used.

C* Circuit common.

Purge

D Contact closure to C completes 40 volts dc

solenoid circuit to purge shielding gas line.

E Contact closure to F indicates coolant flow switch is

closed and recirculating coolant system is
operational.

F* Circuit common.

Jog H** Contact closure to circuit common advances

Retract J** Contact closure to circuit common retracts welding

Touch Sensor ON
And Output Signa

Ref. 803 245-B

*Circuit common is same electrical reference point.
**Speed of Jog + (advance) and Jog − (retract) is 60 ipm for 3 seconds, then it automatically changes to 700 ipm.
Note: A customer supplied matching amphenol plug, factory Part No. 194 847, [Amphenol Part No. 97-3106A-20-33P(B)(621) and strain relief

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

welding wire at wire drive assembly.

wire at wire drive assembly.

K Contact closure to L energizes Touch Sensor

circuitry.

L* Circuit common.

M Part touched +24 volts dc output signal referenced

to circuit common.

OM-210 540 Page 17

3-11. Motor Control Receptacle Functions

G

G

BE

C

A

F

J

K

D

H

Socket Socket Information

A Not used.

B Motor negative (−).

C Tach A .

D Motor positive (+).

E Tach common.

F Gas valve.

G Electrode sense.

H Tach +5 volts dc.

J Tach B .

Ref. 803 245-B

K Gas valve.

OM-210 540 Page 18

3-12. Electrical Service Guide

Failure to f o llow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

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

be available.

60 Hz Three Phase

Input Voltage 208 230 400 460 575
Input Amperes At Rated Output 67 59 34 29 23
Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay

Normal Operating

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .

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

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

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

4

4

2
3

80 70 40 35 25

100 90 50 45 35

4 6 8 10 10

173
(53)

8 8 8 10 10

136

(42)

263
(80)

228

(69)

356

(108)

OM-210 540 Page 19

3-13. Connecting Input Power

2

3

= GND/PE Earth Ground

5

8

3

4

Tools Needed:

5/16 in

! Turn Off welding power source, and

check voltage on input capacitors
according to Section 7-3 before
proceeding.

! Installation must meet all National

and Local Codes − have only qualified
persons make this installation.

! Disconnect and lockout/tagout input

power before connecting input
conductors from unit.

! Make input power connections to the

welding power source first.

! Always connect green or

green/yellow conductor to supply
grounding terminal first, and never to
a line terminal.

1 Input Power Conductors (Customer

Supplied Cord)

Select size and length of conductors using
Section 3-12. Conductors must comply with
national, state, and local electrical codes. If

7

1

Route input power cable

through tubing inside unit.

Route ground conductor through

current transducer to ground terminal.

applicable, use lugs of proper amperage
capacity and correct hole size.

Welding Power Source Input Power
Connections

2 Strain Relief
Install strain relief of proper size for unit and

input conductors. Route conductors (cord)
through strain relief and tighten screws.

S Use large strain relief for input conductor
size 8 and larger.

S Use small strain relief with reducing
washers for input conductor size 10.

Connect input conductors as shown in
illustration.

Route green or green/yellow grounding
conductor through current transducer and
connect to welding power source grounding
terminal first. Then connect input conductors
L1, L2, and L3 to welding power source line
terminals.

Reinstall side panel onto welding power
source.

L1
L2

L3

6

WARNING

ELECTRIC SHOCK can kill;
SIGNIFICANT DC VOLTAGE

exists after removal of
input power.

S Always wait 5 minutes after power
Is turned off before working on unit.
S Check input capacitor voltage, and
be sure it is near 0 before touching
any parts.

Read Owner’s Manual.

Three-Phase Input Connection

803 245-C / Ref. 803 766-A / 218 005-A

Disconnect Device Input Power
Connections

3 Disconnect Device (switch shown in

the OFF position)

4 Green Or Green/Yellow Grounding

Conductor
5 Disconnect Device Grounding Terminal
6 Input Conductors (L1, L2 And L3)
7 Disconnect Device Line Terminals
Connect green or green/yellow grounding

conductor to disconnect device grounding
terminal first.

Connect input conductors L1, L2, and L3 to
disconnect device line terminals.

8 Over-Current Protection
Select type and size of over-current protec-

tion using Section 3-12 (fused disconnect
switch shown).

Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.

OM-210 540 Page 20

3-14. Touch Sensor Operation

The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source.
The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral
receptacle. Turning on touch sensor causes a dc voltage to be present on the welding wire. When welding wire
touches the weldment, the voltage sensing circuit closes, and a +24 volts dc output signal is sent to the robot control
indicating weldment detection. Touch sensor dc voltage on the welding wire is 80 volts DC. As soon as touch sensor
turns on, WIRE LIVE appears on the front panel display.

3-15. Remote Program Select

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

When Remote Program Select is On, a remote device or robot pendant may be used to select programs. When Off,
program selection must be done from the welding power source front panel.

3-16. Remote Program Setting

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

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

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

Program No. Output A Output B Output C

1 Off Off Off
2 On Off Off
3 Off On Off
4 On On Off
5 Off Off On
6 On Off On
7 Off On On
8 On On On

OM-210 540 Page 21

SECTION 4 − OPERATION

4-1. Operational Terms

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

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

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

Program Eight active slots for selection of various processes, wire types, and parameters.
Process A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
MIG CV weld process with individual settings of voltage and wire speed.
Pulse Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory

Accu-pulse Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds.

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

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

RMD (optional) RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of RMD are well

Wire Type Selection of wire type by alloys and classification.
Gas Type Selection of shielding gas being used in application.
Process Set Up Selection procedure for entering program.
Program Load Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).
Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.
Time Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in the Arc On

Arc Length Distance from end of wire electrode to workpiece.
WFS Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In

Amps Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Control Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD

Inductance In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per

Sharp Arc In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory

Adjust Control knob used to change or set parameters and functions.
Sequence Selecting Sequence will allow setting of preflow , start, crater, postflow, and retract times and parameters (only

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

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

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

taught data. Adaptive method is controlled by frequency adjustment.

Adaptive response is controlled by peak and minimum current levels. Benefits are shorter arc lengths, better
puddle control, more tolerant of tip-to-work variation, less audible noise, no arc wandering, allows weld to fill in
at toes increasing travel speed and deposition, and more tolerant to poor fit up and gaps.

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

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

suited to thin materials, improves gap filling and spatter reduction. Provides less heat input into workpiece,
minimizes distortion and allows use of larger diameter wire on thin gauge materials.

and Analog input or the Arc On and No Analog input modes).

pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power level on wire electrode
(one knob control).

(optional).

second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes
the welding puddle more fluid.

pulse data. In RMD (optional) this control will affect the arc in much the same way as inductance.

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

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

OM-210 540 Page 22

4-1 . Operational Terms (Continued)

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

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

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

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

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

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

models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software).

models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software].

models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software).

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

completed. Setting is both speed (IPM) and time (sec), (only available on Auto Axcess models in the Arc On
and Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File
Management software).

automatically feed wire. Default setting is 72 inches at a feed rate of 700 ipm. Pressing jog, purge, or trigger
switch will terminate the auto-threading feature. These values can be changed using a PDA with File
Management/WaveWriter software.

OM-210 540 Page 23

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

1415

1

4

Program

3

Process
Wire Type
Gas Type

5
6

7

Setup Arc Control

V olts Arc Adjust

Wire Speed Amps

Wirefeed
Gas
Contactor

Adjust

13

12

11

10

8

9

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

1 Program Display
Displays the number of the active program.
2 Adjust Knob
Turn the Adjust knob to change program

number, Setup, Arc Control, and weld
parameters.

3 Program Push Button LED
The LED lights when the Program Push

Button is active.
4 Program Push Button
Press push button (LED lights) and turn Adjust

knob to select active program.
The letter C is displayed with the program

number i f the program has been changed from
the factory settings using the optional PDA
with File Management/WaveWriter software
(see File Management/WaveWriter Owner’s
Manual).

. The program cannot be changed through

the front panel while welding.

Press and hold button to see program name.
Custom programs are named using optional

2

PDA with File Management/WaveWriter
software. Program name is shown in upper
and lower displays (items 13 and 15).

5 Setup Mode Indicators
The lit LED indicates which setup mode is

active. Setup mode parameters are shown in
Display Windows (see Items 13 and 15).

Process LED

When this LED is lit, turn the Adjust knob to
select the desired weld process. Choices
include pulse welding (displayed as PULS),
Accu-pulse, MIG welding (MIG), and Accu
Puls/RMD [Regulated Metal Deposition
(optional)].

Wire Type LED

When this LED is lit, turn the Adjust knob to
select the desired wire type, wire alloy, and
size. Wire type and size choices vary
according to the selected weld process.
Choices may include steel (displayed as
STL), stainless steel (SS), metal core
(MCOR), aluminum (ALUM). See Table 4-1
for all wire abbreviations.

198 993

Gas Type LED

When this LED is lit, turn the Adjust knob to
select the desired weld gas. Gas type choices
vary according to the selected weld process.

See Table 4-1 for all gas abbreviations.
6 Setup Push Button LED
The LED lights to indicate one of the setup

modes is active.
7 Setup Push Button
Press button to select Process, Wire Type,

Wire Diameter, or Gas Type parameters.

. In order for selections to be retained in

memory, the Setup push button must be

pressed six times before any other push

button i s pressed: once to select Process,

again t o select Wire Type, again to select

Wire Alloy, again to select Wire Size,

again t o select Gas Type, and a sixth time

to store selections in memory. The

displays will temporarily show “PROG

LOAD” to indicate the data is being stored

in memory.

OM-210 540 Page 24

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

439

8 Arc Control LED
The LED lights to indicate the Arc Control

button i s active. Light goes out when button is
inactive.

9 Arc Control Push Button
This push button allows fine tuning inductance

for MIG programs, and Arc Control for
programs other than MIG. When the push
button i s pressed, the upper display (item 15)
shows INDU for inductance, or ARC for Arc
Control to indicate which parameter is
selected for change. The range of possible
values is 0-99 for inductance, and 0-50 for arc
control. Turn the Adjust knob to change the
parameter value. Press button to deactivate
arc control mode (LED goes out).

10 Wire Feed/Gas/Contactor LEDs
The Wirefeed LED lights when the wire feeder

is energized. For example, when the front
panel Jog or Retract button is pressed, the
Wirefeed LED lights.

The Gas LED lights when the gas valve is
energized.

The Contactor LED lights when the output
contactor is energized, making the weld
output terminals live.

11 Wire Speed And Amps LED’s
The lit LED indicates whether wire speed or

amps are being displayed.
12 Wire Feed Speed/Amps Display Push

Button
13 Lower Display
Press Wire Feed Speed/Amps Display button

to show weld amperage or wire feed speed in
lower display (the applicable LED under the
lower display lights to indicate which is
shown). When welding, actual value is shown.

If amperage was selected for display, the unit
will show actual welding amperage prior to
and while welding unless the the unit is in
Display Command Values mode. Only wire
speed command will be displayed while
welding if the unit is set in Display Command
Values mode, even if the Wire Feed
Speed/Amps Display button is pressed.

. Displays show actual or command values

as determined by configuration menu

when using a PDA with File Management/

WaveWriter software. Command values

are displayed prior to welding and actual

values are displayed while welding unless

a PDA with File Management software

was used to set the unit in the ”Display
Command Values” mode. In the Display
Command Values mode, command
values are displayed while welding.

. If a PDA with File Management/WaveWriter

software i s used to c hange wire feed units
(IPM, MPM) or display welding information
(command or actual),save the changes and
then turn the power to the unit off and then
on again for the c hanges to be carried out
by the unit.

14 Volts And Arc Adjust LED’s
The lit LED indicates whether voltage or arc

length is being displayed.
15 Upper Display
The upper display shows different information

depending on the active function of the unit
and the weld process being used. When the
display shows voltage (for a MIG process),
the Volts LED lights. When it shows arc adjust
[for a pulsed and RMD (optional) weld
process], the Arc Adjust LED lights. However,
during any weld process (MIG and pulse), the
unit will display actual arc voltage unless a
PDA with File Management/WaveWriter
software has set the unit in the ”Display
Command Values” mode.

Table 4-1. Welding Wire And Gas Abbreviations*

Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation

Steel STL E70, E100, E120 100% CO2,

90% Argon/10% CO2,
85% Argon/15% CO2,
75% Argon/25% CO2,

95% Argon/5% CO2,

95% Argon /5% O2,

98% Argon/2% O

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

(81Ar/18HE/1CO

2

2

2

CO2

C10
C15
C25

C5
OX5
OX2

OX2

Tri Gas

Accu-pulse)

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

2

Tri Gas

MIG/RMD/Accu-pulse)

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

90% Argon/10% CO

98% Argon/2% O

2

2

C10

OX2

Aluminum ALUM 4XXX, 5XXX 100% Argon ARGN

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

OM-210 540 Page 25

Table 4-2. Robot Abbreviations

Manufacturer

ABB ABB

Fanuc FANU

Daihen DAHN

Kawasaki KAWA

Kuka KUKA
Comau COMU
Hitachi HCHI

Nachi NCHI

Panasonic PANA

Motorman MOTO

Robot Adapter DTEC

Detect Disabled OFF

None Robt DTEC

4-4. Front Panel Switches

Robot Abbreviation

6

3

1

1 Power Switch
Turns unit On or Off.
The power-up sequence may last up to 30

seconds before the unit is ready to weld.
During power-up, the front panel will display
messages indicating the status of the unit. The
first message is :

NET
WAIT

NET WAIT is an abbreviation for ”network
updating” and means the internal control
network is powering up. The next message is

XXXX (Robot Type)
XXXX identifies the robot adapter being used

as identified by the unit (see Table 4-2 for a list
of robot adapters that could be displayed). To
ensure proper operation of the system, verify
the robot displayed corresponds to the actual
robot being used. The final message is

2

AUTO
450

AUTO 450 indicates the software being
loaded.

2 Contactor L E D
Contactor LED illuminates when weld output is

energized.
3 Purge Push Button
Press button to purge gas line.
4 Gas LED
Gas LED illuminates when Purge push button

is pressed.
5 Jog Push Button
Press button to jog wire.

4
8
5

9

7

Ref. 803 246-B

6 Wirefeed LED
Wirefeed LED illuminates when wire feeds or

retracts.

7 Retract Push Button
Press button to retract wire. Wirefeed LED

illuminates when Retract push button is
pressed.

Auto-Threading feature is activated by
pressing the Jog and Retract buttons
simultaneously. Pressing the Jog, Purge, or
trigger switch will turn off the Auto-Threading
feature.

8 PDA Port
9 PC Port

OM-210 540 Page 26

4-5. Robot Calibration Mode

XXXX

Turn unit On. Unit displays abbreviated name of robot

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

of robot adapters that could be displayed).

Use the robot calibration mode to
custom-calibrate the power source to
the robot command signals. This
ensures the wire speed, voltage, and
arc adjust are the same on the robot
pendant as on the powe r s o u r c e .

. The factory recommendation is to

perform the calibration on all
installations or code updates.

Follow this procedure if the factory
settings are not as accurate as
desired. Synchronization of the robot
and power source signals makes
installation easier and improves the
operation of the system.

. The robot pendant must have

Weld enabled, and there can be
no start/stop crater conditions set
in the robot.

The calibration mode will execute as a
”dry run” from the operator’s
perspective. The welding power
source provides the robot with
feedback s o the robot thinks a weld is
underway, yet the robot torch need not
move during the calibration.

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

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

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

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

CIRCULER

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

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

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

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

Schedule 1

10.0 Volts
100 IPM

Schedule 2

44.0 Volts
1000 IPM

. If you wish to stop the calibration

procedure, turn unit input power
off and then on again.

If the calibration is performed correctly
the ROBT CAL message st op s b e i n g
displayed; however, if it is performed
incorrectly, the message remains on
the display.

To start the calibration procedure over
again, turn unit input power off and
then on again following the calibration
setup steps following the calibration
setup steps.

When the robot calibration mode ends, the ROBT CAL message

stops and the unit will display normal front panel information.

198 993

OM-210 540 Page 27

4-6. Robot Auto-Calibration Sample Programs

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

welding power source is looking for 2 distinct welding conditions. If there is a “start power” condition, the welding power source will equate this
as the first condition and fail to execute Auto-Cal correctly. If there is a “crater fill” condition, the welding power source will equate this as the second
condition and fail to execute Auto-Cal correctly.

Actual Motoman Welder Condition File

<Welding Current Output Char.>
NO. REF (V) MEASURE (A)

01 0.01 1
02 7.00 500
03 13.99 999
04 0.00 000

<Welding Voltage Output Char.>
NO. REF (V) MEASURE (V)

01 0.14 0.5
02 7.00 25.0
03 14.00 50.0
04

Sample Auto-Calibration Routine For Motoman Robot

0000 NOP
0001 Mov J
0002 AWELD 1.40 (AWELD direct input of 1.40Volts = 100 ipm)
0003 VWELD 2.80 (VWELD direct input of 2.80Volts = 10.0 volts)
0004 Arcon
0005 Timer T=10.00
0006 Arcof
0007 AWELD 14.00 (AWELD direct input of 14.00Volts = 1000 ipm)
0008 VWELD 12.32 (VWELD direct input of 12.32Volts = 44.0 volts)
0009 Arcon
0010 Timer T=10.00
0011 Arcof
0012 End

OM-210 540 Page 28

Sample Auto-Calibration Routine For Fanuc Robot

1: Call Safehome
2: J P[1] 40% Fine

Arcstart [10.0Volts, 100.0IPM]

3: L P[2] 10.0 sec Fine

Arc End [0.0Volts, 0.0IPM, 0.0Sec]
4: Wait 1.00 (Sec)
5: J P[3] 40% Fine

Arcstart [44.0Volts, 1000.0IPM]
6: L P[4] 10.0 sec Fine

Arc End [0.0Volts, 0.0IPM, 0.0Sec]
7: Call Safehome

Sample Auto-Calibration Routine For ABB Robot

Move J home, v500, z50, tweldgun;
Arcl \ on, *, v500, sm1, wd1, wv0, z50, tweldgun;
Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;
WaitTime 5;
Arcl \ on, *, v500, sm1, wd2, wv0, z50, tweldgun;
Arcl \ off, *, v500, sm1, wd2, wv0, z50, tweldgun;
Move J home, v500, z50, tweldgun;

*Seam Data values must all be set at zero.

Weld Data 1:

weld_sched:=0 weld_sched:=0
weld_speed:=5 weld_speed:=5

weld_voltage:=10 weld_voltage:=44

weld_wfs:=100 weld_wfs:=1000

org_weldspeed:=0 org_weldspeed:=0

org_weldvoltage:=0 org_weldvoltage:=0

org_weldwfeed:=0 org_weldwfeed:=0

Weld Data 2:

OM-210 540 Page 29

4-7. Reset Mode

Enter reset mode by turning power On and pressing

the Program Push Button until the RST NO message

is displayed. RST NO message will not display until

after the power-up sequence is completed

(approximately 20 seconds).

RST
NO

. Reset mode is not active when

Program Lock is enabled.

The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.

. System configuration data will be

lost during the Reset operation.

RST
YES

Rotate Adjust knob to change NO

to YES.

RST

YES

Press the Arc Control button to

confirm the reset.

The reset message is displayed for

2 seconds while factory program

settings are being reloaded.

During the reset mode the following

factory default programs are loaded

into the unit:

Program 1 Pulse

.035 Mild Steel
90% Argon, 10% CO

Program 2 MIG

.035 Mild Steel
75% Argon, 25% CO

Program 3 Accu-pulse

.035 Mild Steel
90% Argon, 10% O2

Program 4 Pulse

.045 Mild Steel
90% Argon, 10% CO

Program 5 MIG

.045 Mild Steel
75% Argon, 25% CO

Program 6 Accu-pulse

.045 Mild Steel
90% Argon, 10% O2

Program 7 Pulse

.052 Mild Steel
90% Argon, 10% CO

Program 8 MIG

.052 Mild Steel
75% Argon, 25% CO

CYCL

PWR

Cycl Pwr message appears on the display

when programs complete loading.

Turn power off, wait 10 seconds, and turn

power back on again to complete the reset

. After Reset is complete, be sure to load

appropriate programs that contain the
correct wire size, process, and shielding gas
for the welding operation

2

2

2

2

2

2

operation.

198 993 / 803 246-B

OM-210 540 Page 30

SECTION 5 − MAINTENANCE

Every

3

5-1. Routine Maintenance

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

3

Months

Every

6

Months

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

nl Cords nl Gun Cables

OR

~ Drive Rolls ~ Inside Unit

5-2. Blowing Out Inside Of Unit

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

! Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow
through front and back louvers as
shown.

Ref. 803 244-B

OM-210 540 Page 31

SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING

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

6-1. Symbol Usage

OM-210 540S - 2007−10, safety_stm 2007−04

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

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

NOTICE − Indicates statements not related to personal injury .

6-2. Servicing Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard.

Only qualified persons should test, maintain, and repair this
unit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

D Do not touch live electrical parts.
D Turn Off welding power source an d wi re f ee de r

and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re­ceptacle, o r stop engine before servicing unless the procedure spe­cifically requires an energized unit.

D Insulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

D Do not leave live unit unattended.
D If this procedure requires an energized unit, have only personnel

familiar with and following standard safety practices do the job.

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

hands inside unit. Keep one hand free.

D Disconnect input power conductors from deenergized supply line

BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.

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

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

. 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.

FIRE OR EXPLOSION hazard.

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

surfaces.

D Do not service unit near flammables.

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or face

shield during servicing.

D Be careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

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

equipment.

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

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

EXPLODING PARTS can cause injury.

D Failed parts can explode or cause other parts to

explode when power is applied to inverters.

D Always wear a face shield and long sleeves

when servicing inverters.

SHOCK HAZARD from testing.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

D Use proper static-proof bags and boxes to

OM-210 540 Page 32

boards or parts.

store, move, or ship PC boards.

D Turn Off welding power source an d wi re f ee de r

or stop engine before making or changing me­ter lead connections.

D Use at least one meter lead that has a self-

retaining spring clip such as an alligator clip.

D Read instructions for test equipment.

FALLING UNIT can cause injury.

OVERUSE can cause OVERHEATING.

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.

MOVING PARTS can cause injury.

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

rolls.

D Have only qualified persons remove doors,

panels, covers, or guards for maintenance as

necessary.

D Keep hands, hair, loose clothing, and tools

away from moving parts.

D Reinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away from serv-

icing areas until consulting their doctor and the

device manufacturer.

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.

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 install, test, and service
H.F. producing units.

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.

READ INSTRUCTIONS.

D Use Testing Booklet (Part No. 150 853) when

servicing this unit.

D Consult the Owner’s Manual for welding safety

precautions.

D Use only genuine replacement parts from the

manufacturer.

6-3. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

6-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

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

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

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

4. Keep welding power source and cables as far away from opera­tor as practical.

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

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-210 540 Page 33

SECTION 7 − TROUBLESHOOTING

7-1. Set Value Mode

Program

V olts Arc Adjust

Wire Speed Amps

Process
Wire Type
Gas Type

1

Setup Arc Control

Adjust

Wirefeed
Gas
Contactor

3

4

2

The Set Value mode is a troubleshooting tool
that allows certain robot command values to
be manually over-ridden.

1 Setup Push Button
2 Arc Control Push Button
3 Adjust Knob
4 Wire Feed Speed/Amps Display Push

Button

OM-210 540 Page 34

Enter the Set Value mode by pressing the
Setup and Arc Control push buttons at the
same time. When in the Set Value mode the
display windows briefly shows SET VALU and
the blinking LED’s under the display windows
indicate whether Volts, Arc Adjust, or Wire
Speed can be changed turning the Adjust
knob.

Depending on the defined weld process,
either volts (MIG) or arc adjust [pulse,
Accu-pulse, or RMD (optional)] can be
changed i n th e top display. Wire speed can be

changed in the bottom display. Press the Wire
Feed Speed/Amps push button to toggle
between selecting information in the top
display or bottom display. The LED under the
active display will blink to indicate the value
that can be changed.

Rotate the Adjust knob to change values.
Exit the Set V alue mode by pressing the Setup

and Arc Control push buttons at the same time
or turning power source off and then back on
again.

7-2. Diagnostics

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

ERR

TACH

Indicates a
tachometer error.

ERR

COOL

Indicates a coolant
flow error.

ERR TACH

• Tach error for Tach A occurs 2 seconds
after the loss of tachometer feedback. The
motor speed is regulated through the
monitoring of voltage and current. Press
Jog/Purge button to clear error.

• Tach error for Tach B occurs 2 seconds
after the loss of tachometer feedback. The
motor speed is regulated through the
monitoring of voltage and current. Press
Jog/Purge button to clear error.

ERR MOTR

• The motor error indicates that the motor
has been drawing too much current for too
long. To remedy this, reduce the wire feed
speed or the wire feeder torque load/duty
cycle. Press Jog/Purge button to clear error .

ERR WFS

• The wire feed speed error indicates actual
wire feed speed does not match wire feed
speed command. Press Jog/Purge button
to clear error.

ERR STRT

• The start error, when enabled, occurs if the
trigger is held longer than three seconds
without an arc start. The error may be
cleared by releasing the trigger, and
pressing the Jog/Purge button.

ERR

MOTR

Indicates a motor
error.

ERR

GND

Indicates a ground
current error.

ERR

WFS

Indicates a wire
feed speed error.

ERR

STUK

Indicates a wire
stuck error.

ERR STOP

• The stop error occurs as result of
obstructions in the wire feed system or a
faulty wire drive system. Check wire feed
and wire drive systems. Press Jog/Purge
button to clear error.

ERR FLOW

• The flow error indicates no gas flow to the
gun. The error may be reset by
reestablishing gas flow to the gun, and then
pressing the Jog/Purge button.

ERR COOL

• The cool error indicates no coolant flow in
water flow switch option. The error may be
reset by reestablishing coolant flow to the
gun, and then pressing the Jog/Purge
button.

ERR GND

• The ground current error occurs if weld
current is detected in the earth ground
connection. May be caused by a conductor
making contact with unit chassis. Check
and repair feeder weld connections. Turn
power off and back on to clear error.

ERR

STRT

Indicates an arc
start error.

ERR

TEMP

Indicates a
temperature error.

ERR

STOP

Indicates an arc
stop error.

ERR
LINE

Indicates a line
error.

ERR STUK

• The stuck error occurs if the welding wire
sticks to the workpiece at the end of a weld.
May be caused by poor weld conditions.
The error may be cleared by cutting wire
from workpiece, and pressing the Jog/
Purge button.

ERR TEMP

• The temperature error indicates welding
power source has overheated and
shutdown. The error may be cleared by
allowing unit to cool down, and pressing the
Jog/Purge button. If problem persists,
check fan motors and thermistors for proper
operation. If unit is not overheated, check in­put line voltage. If input line voltage is okay,
contact nearest factory authorized Service
Agent.

ERR LINE

• The line error indicates input power is
outside of unit operating range. Check and
correct input power. Press Jog/Purge
button to clear error.

ERR ARC

• The arc error indicates an arc outage
occurred possibly from a wire feeder error
or power source error. Check wire feeder
and power source. Press Jog/Purge button
to clear error.

ERR

FLOW

Indicates a gas
flow error.

ERR
ARC

Indicates an arc
error.

OM-210 540 Page 35

7-2. Diagnostics (Continued)

WELD

WAIT

Indicates a weld
cycle wait error.

RMD

DONE

Indicates RMD
demo is done.

WELD WAIT

• The weld wait error indicates unit was not
ready for a weld sequence. Press Jog/
Purge button to clear error.

MOTR COM

• The motor communication error indi-
cates motor board lost data communica­tions. Press Jog/Purge button to clear error.
If condition persists, contact nearest factory
authorized service agent.

PLS WAIT

• The uim communication error indicates
user interface board lost data
communications. Press Jog/Purge button
to clear error. If condition persists, contact
nearest factory authorized service agent.

LOW WFS

• The low wire feed speed error indicates
actual wire feed speed is lower than wire
feed speed command. Check for
obstructions in the wire feed system or a
faulty wire drive system. Press Jog/Purge
button to clear error.

MOTR

COM

Indicates a motor
communication error.

OVER
AVG

Indicates an over
average current error.

PLS

WAIT

Indicates a UIM
communication error.

UNIT

COMM

Indicates a CRC
PCM bus error.

ROBT MEM

• The robot memory error indicates robot
lost memory data. Press Jog/Purge button
to clear error.

E STOP

• The emergency stop error occurs if the
user presses an emergency stop button.
Reset the emergency stop button and press
Jog/Purge button to clear error. Only applies
to units equipped with E stop option.

RMD DONE

• The RMD done message indicates the
RMD demo is completed. Pressing
Jog/Purge button will change the screen to
CYCL PWR on the display. Turn unit power
off and back on again.

OVER AVG

• The over average error indicates that
current is outside the average range for t h e
set program parameters. Check and correct
program parameters. Press Jog/Purge
button to clear error.

LOW
WFS

Indicates a low WFS
command error.

OVER

CRNT

Indicates an
overcurrent error.

ROBT

MEM

Indicates a CRC
robot memory error.

UNIT COMM

• The unit communication error indicates
the data bus on the PCM board is not
functioning properly. Press Jog/Purge
button to clear error.

OVER CRNT

• The over current error indicates welding
power source primary current of the inverter
is too high. Turn welding power source off

and disconnect unit for servicing.
Attempting to reset the display to
continue welding may further damage
internal components. A complete

prepower check of the unit is needed
including resistance measurements of R1
and R8 resistors on welding power source
Interconnect board. Resistors should
measure 30K ohms. Visually inspect
electrolytic capacitors C1 and C2 for any
possible damage. In the event of an over
voltage condition, R1 and R8 could open
potentially causing an imbalance in the
power circuit. This condition would create
excessive current in the inverter primary
transformer and result in the OVER CRNT
error.

E

STOP

Indicates an
emergency stop error.

OM-210 540 Page 36

7-2. Diagnostics (Continued)

REL
TRIG

Indicates a contactor
on error.

REL TRIG

• The release trigger error indicates the
user held the gun trigger after an E stop was
reset causing the contactor to remain on.
Press Jog/Purge button to clear error.

TRIG STUK

• The trigger stuck error indicates the user
held the gun trigger during power up.
Release trigger and turn power off and back
on.

TRIG
STUK

Indicates a trigger
closed error.

ERR

UNKN

Indicates an
unknown error.

ERR UNKN

• The unknown error indicates an error was
sent from the PCM board to the UIM, but
error condition is unknown. Make sure
welding power source is isolated from the
welding fixture. Press Jog/Purge button to
clear error.

OM-210 540 Page 37

7-3. Removing Cover and Measuring Input Capacitor Voltage

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

significant DC voltage can remain on capacitors
after unit is Off. Always check the voltage on both

Tools Needed:

5/16 in

inverter assemblies as shown to be sure the input
capacitors have discharged before working on unit.

1

2

Turn Off welding power source, a n d
disconnect input power.

Remove cover
1 Power Interconnect Board

PC2
2 Voltmeter
Measure the dc voltage across the

+ bus terminal and − bus terminal on
PC2 as shown until voltage drops to
near 0 (zero) volts. Measure input
capacitor voltage on both inverter
assemblies before proceeding.

3 Typical Bleeder Resistor
An example of a typical bleeder

resistor is shown on this page.
Proceed with job inside unit.

Reinstall cover when finished.

+ lead to left bus terminal, − lead to right bus terminal

1

2

+ lead to left bus terminal, − lead to right bus terminal

3

Typical Bleeder Resistor

25 to 1000 ohm, 5

watt resistor

OM-210 540 Page 38

#16 AWG 1000 volts dc
insulation rating, approx

3 in (76 mm) leads

802 985 / Ref. 803 250-C

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

1

1 Process Control Module PC4
Diagnostic LED’ s are visible inside unit,

located o n PC4 mounted on the top tray.
Refer to Section 7-5 for information on

diagnostic LED’s.
Reinstall cover after checking diagnostic

LED’s.

LED1

LED2

LED3
LED4

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

LED Status Diagnosis

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

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

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

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

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

Off See Network Status Table in Section 7-12

216 956-A / Ref. 803 250-C

OM-210 540 Page 39

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

1 Wire Feed Module PC6

2

1

LED1 LED2

LED3

LED4

Diagnostic LED’s are visible inside
unit, located on PC6 mounted on
the top tray assembly.

Refer to Section 7-7 for information
on diagnostic LED’s.

Reinstall top cover after checking
diagnostic LED’s.

2 Dip Switch S1
Dip switches are used to identify

each circuit board on the internal
network. Dip switch settings are
different for each circuit board. For
proper operation, do not change dip
settings from those shown.

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

LED Status Diagnosis

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

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

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

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

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

Off See Network Status Table in Section 7-12

OM-210 540 Page 40

217 333-B / 803 251-B

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

2

3

LED1

LED2

1

1 User Interface Module PC7
Diagnostic LED’s are visible inside unit,

located on PC7 mounted behind the front
panel.

Refer to Section 7-9 for information on
diagnostic LED’s.

Reinstall cover after checking diagnostic
LED’s.

2 Dip Switch S1
3 Dip Switch S2

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

LED Status Diagnosis

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

Off See Network Status Table in Section 7-12

218 559-A / 803 251-B

Dip switches are used to identify each
circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.

OM-210 540 Page 41

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

LED1
LED2
LED3
LED4

LED5
LED6

LED7
LED8

LED9
LED10

LED33

1

LED20

LED19 LED18

LED11

LED13

LED12

LED15

LED16 LED21 LED22 LED23 LED24 LED26 LED29

LED17

LED14

LED25

LED27

LED28

LED31

LED30

2

LED32

1 Automation Interface Module PC9
Diagnostic LED’s are visible inside unit,

located o n PC9 mounted on left side.
Refer to Section 7-9 for information on

diagnostic LED’s.

OM-210 540 Page 42

Reinstall cover after checking diagnostic
LED’s.

2 Dip Switch S4

216 958-A / Ref. 803 250-C

Dip switches are used to identify each
circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.

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

LED Status Diagnosis

1 On Input signal On from robot for jog advance

Off Input signal Off from robot for no jog advance

2 On Input signal On from robot to energize contactor

Off Input signal Off from robot to not energize contactor

3 On Input signal On remote program A selected

Off Input signal Off remote program A not selected

4 On Input signal On remote program C selected

Off Input signal Off remote program C not selected

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

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

6 On Spare 1 not assigned

Off Spare 1 not assigned

7 On Input signal On Autoset-C selected

Off Input signal Off Autoset-C not selected

8 On Input signal On Autoset-B selected

Off Input signal Off Autoset-B not selected

9 On Input signal On Remote Jog on from peripheral plug

Off Input signal Off Remote Jog off from peripheral plug

10 On Input signal On Remote Purge on from peripheral plug

Off Input signal Off Remote Purge off from peripheral plug

11 On Input signal On from robot for jog retract

Off Input signal Off from robot for no jog retract

12 On Input signal On from robot for purge

Off Input signal Off from robot for no purge

13 On Input signal On remote program B selected

Off Input signal Off remote program B not selected

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

Off Input signal Off T ouch Sensor of f from robot or peripheral plug

15 On Spare 0 not assigned

Off Spare 0 not assigned

16 On Spare 2 not assigned

Off Spare 2 not assigned

17 On Input signal On Autoset-A selected

Off Input signal Off Autoset-A not selected

18 On Input signal On Autoset-D selected

Off Input signal Off Autoset-D not selected

19 On Input signal On Remote Retract on from peripheral plug

Off Input signal Off Remote Retract off from peripheral plug

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

Off Input signal Off Remote Water Flow off from peripheral plug

21 On Input signal On from robot for no emergency stop

Off Input signal Off from robot for emergency stop

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

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

in operating mode preventing the weld ready signal from being enabled

OM-210 540 Page 43

LED DiagnosisStatus

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

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

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

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

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

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

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

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

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

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

29 On Input signal on from relay K6 for arc detected

Off Input signal off from relay K6 for no arc detected

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

Off See Network Status Table in Section 7-12

32 On Input signal on for aux. relay energized

Off Input signal off for aux. relay energized

33 On Input signal on touch sensor touch detected

Off Input signal off touch sensor touch not detected

OM-210 540 Page 44

7-12. Network And Module Status LED’s

A. Network Status LED’s

The following are network status LED’s:
LED1 on the UIM circuit board
LED4 on the WFM and PCM circuit boards
LED30 on the AIM circuit board.

Status Diagnosis

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

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

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

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

B. Module Status LED’s

The following are module status LED’s:
LED2 on the UIM circuit board
LED3 on the WFM and PCM circuit boards
LED31 on the AIM circuit board.

Status Diagnosis

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

Green The circuit board is operating normally.

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

Red The circuit board has encountered an unrecoverable fault.

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

OM-210 540 Page 45

7-13. Troubleshooting

errors displayed.

constant current power source.

Trouble Remedy

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

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

No weld output; meter display on with no
error displayed.

Erratic or improper weld output with no

No 115 volts AC at the duplex receptacle. Reset supplementary protector CB1 (see Section 3-7).
Wire does not feed. Check supplementary protector CB2 and reset if necessary (see Section 3-7).

Wire feeds erratically. Readjust hub tension.

Wire fe e d s a s s o o n a s p o w e r i s s u p p l i e d . Check gun trigger. See gun Owner’s Manual.
Wire stubbing on low end using a

Gas does not flow or does not stop flow­ing; wire feeds.

Wire burns back to gun contact tip when
using electrode negative (straight
polarity) process.

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

Use proper size and type of weld cable (see Section 3-9).
Check that proper program for wire size, process, and shielding gas is loaded.
Clean and tighten all weld connections.

Check motor control cable connections.

Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.

Increase output setting of the power source.
Check voltage sense lead connection, clean and tighten if necessary.
Check gas valve and flow meter.

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

OM-210 540 Page 46

Notes

OM-210 540 Page 47

SECTION 8 − ELECTRICAL DIAGRAMS

OM-210 540 Page 48

Figure 8-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)

207 903-G (Part 1 Of 2)

OM-210 540 Page 49

OM-210 540 Page 50

Figure 8-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)

207 903-G (Part 2 Of 2)

OM-210 540 Page 51

OM-210 540 Page 52

Figure 8-3. Circuit Diagram For 72 Pin Robot Interface

219 266-C

OM-210 540 Page 53

OM-210 540 Page 54

Figure 8-4. Circuit Diagram For Peripheral/Motor Interface

219 267-B

OM-210 540 Page 55

. Hardware is common and

not available unless listed.

SECTION 9 − PARTS LIST

2

1

3

4 − Fig 9-3

5 − Fig 9-2

6

7 − Fig 9-4

8

16 − Fig 9-5

15

15

14

13

12

17

19

5

10

18

11

9

18

8

OM-210 540 Page 56

Ref. 803 247-D

Figure 9-1. Main Assembly

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

Figure 9-1. Main Assembly

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

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

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

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

5 IM1, IM2 222959 MODULE, inverter assy (300A) (Fig 9-2) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 198961 Panel, Module Divider 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

8 227793 Panel, Side W/Insulator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

10 W1 180270 Contactor, DEF PRP 40A 3P 24VAC Coil W/Boxlug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

15 213372 Filter Assy, Secondary 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

13

12
11

10

14

15

2

3

6

7

32

1

4

5

6

7

8

9

33

31

30

29

13

28

Figure 9-2. Windtunnel Assembly LH And RH

34

26

27

35

17

18

. Hardware is common and

not available unless listed.

16

19

20

21

23

22

23

38

24

37

25

23

36

802 955-A

OM-210 540 Page 57

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

24 RT1,RT2.RT3 214015 Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead 3. . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-210 540 Page 58

1

Part

Dia.

Item

ty

2

3

. Hardware is common and

not available unless listed.

4

No.

Mkgs.

11

10

9

5

6

7

8

802 916-B

Figure 9-3. Top Tray Assembly

No.

Description

Quanti

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

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

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

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

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

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

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

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

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

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

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

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

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-210 540 Page 59

. Hardware is common and

Part

Dia.

Item

ty

not available unless listed.

4

3

2

1

15

5

6

8

7

9

10

11

14

13

12

803 248-D

Figure 9-4. Rear Panel Assembly

No.

Mkgs.

No.

Description

Quanti

Figure 9-4. Rear Panel Assembly (Fig 9-1 Item 8)

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

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

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

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

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

6 207894 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

8 210505 Nameplate, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-210 540 Page 60

. Hardware is common and

Part

Dia.

Item

ty

2

1

11

26

10

3

24

25

4

6

5

not available unless listed.

7

20

21

22

20

23

18

19

Figure 9-5. Front Panel Assembly

9

10

13

17

16

15

12

10

8

11

14

12

Ref. 803 249-C

No.

Mkgs.

No.

Description

Figure 9-5. Front Panel Assembly (Fig 9-1 Item 14)

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

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

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

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

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

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

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

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

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

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

8 FM 196313 Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

12 025248 Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 207897 Bus Bar, Output 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 210866 Terminal, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-210 540 Page 61

Quanti

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

Figure 9-5. Front Panel Assembly (Fig 9-1 Item 14) (Continued)

16 216966 Cover, Connector D-sub 9 pin Male w/Chain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 216965 Cover, Connector D-sub 9 skt Female w/Chain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 219843 Label, Volt Sense 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 207896 Box, Louver 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 186621 Boot, Generic 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

22 207902 Nameplate, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 210865 Terminal, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 207893 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 210483 Bracket, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 210358 Bolt, eye shld thd stem .500−13 X 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-210 540 Page 62

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, 2007

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

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

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 th e
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

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

whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT , TORT OR ANY
OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2007−01

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 He adquarte rs− USA

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

European He a dquart er s −
United K ingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during
shipment.

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

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