Miller Electric Axcess 300 User Manual

OM-230 032C 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

™

Axcess 300

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 − DEFINITIONS 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Manufacturer’s Warning Label Definitions 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. WEEE Label 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Symbols And Definitions 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Manufacturer’s Rating Label 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions And Weight 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Duty Cycle And Overheating 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Volt-Ampere Curves 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Selecting A Location 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connection Diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Rear Panel Receptacles And Supplementary Protectors 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Connecting To Weld Terminals 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Network Wire Feeder Receptacle Functions 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Electrical Service Guide 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Connecting Input Power 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − RECOMMENDED SETUP PROCEDURES 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Selecting Weld Cable Sizes* 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Welding Circuit 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Arranging Welding Cables To Reduce Welding Circuit Inductance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Using Multiple Welding Power Sources 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs 26 . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATION 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Switches 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Options 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Blowing Out Inside Of Unit 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Symbol Usage 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Servicing Hazards 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. California Proposition 65 Warnings 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. EMF Information 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 9 − TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Removing Cover and Measuring Input Capacitor Voltage 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Weld Process Board PC4 Diagnostic LED’s 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Diagnostic LED’s On Process Board PC4 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Network And Module Status LED’s 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Troubleshooting 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − PARTS LIST 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

Declaration of Conformity for

European Community (CE) Products

. This information is provided for units with CE certification (see rating label on unit).

Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: [phone] Via Privata Iseo 6/E

20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]

European Contact Signature:

Declares that this product: Axcesst 300

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Standards

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.

IEC 60974-10 August 2002

Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1

Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1

Insulation Coordination For Equipment Within Low-Voltage Systems:

Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1

The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

dec_stat_1/07

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-230 032 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-230 032 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-230 032 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-230 032 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-230 032 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-230 032 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

v-

on

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 ris-

quent 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-230 032 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 FRÉ-

QUENCE (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-230 032 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-230 032 Page 9

OM-230 032 Page 10

SECTION 3 − DEFINITIONS

3-1. Manufacturer ’s Warning Label Definitions

1 1.1 1.2 1.3

2 2.1

3 3.1 3.2 3.3

4 4.1

56

+

2.2

+

2.3

+

+

S-179 310

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

1 Electric shock from welding

electrode or wiring can kill.

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

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

1.3 Disconnect input plug or
power before working on
machine.

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the
fumes.

2.2 Use forced ventilation or local
exhaust to remove the fumes.

2.3 Use ventilating fan to remove
fumes.

3 Welding sparks can cause

explosion or fire.

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

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

3.3 Do not weld on drums or any
closed containers.

4 Arc rays can burn eyes and

injure skin.

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

5 Become trained and read the

instructions before working on
the machine or welding.

6 Do not remove or paint over

(cover) the label.

1/96

OM-230 032 Page 11

2 3 4 5 6

1

7 8 9 10

1 Warning! Watch Out! There are

possible hazards as shown by the

symbols.
2 Electric shock from wiring can kill.
3 Disconnect input plug or power

before working on machine.
4 Hazardous voltage remains on input

capacitors after power is turned off.

V

> 5 min

Do not touch fully charged
capacitors.

5 Always wait 5 minutes after power is

turned off before working on unit, OR

6 Check input capacitor voltage, and

be sure it is near 0 before touching
any parts.

7 When power is applied failed parts

V

V

219844−A

4/04

can explode or cause other parts to
explode.

8 Flying pieces of parts can cause

injury. Always wear a face shield
when servicing unit.

9 Always wear long sleeves and button

your collar when servicing unit.

10 After taking proper precautions as

shown, connect power to unit.

2345

3-2. WEEE Label

∠ = <60

∠

1

°

S-179 309-A

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Falling equipment can cause

injury and damage to unit.

3 Always lift and support unit

using both eye bolts. Keep
angle of lifting device less
than 60 degrees.

4 Use a proper cart to move

unit.

5 Do not use one eye bolt to lift

or support unit.

1/96

Do not discard this product with
general waste.

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

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

OM-230 032 Page 12

3-3. Symbols And Definitions

U

U

IP

I

%

I

x

I

S

A

0

Hz

1ma

Amperage

Output Circuit Breaker Remote On

Off Positive Negative Voltage Input

Arc Force Constant Voltage Inductance

Increase Line Connection

Rated No Load

Voltage (A verage)

Hertz

Pulsed Single Phase Three Phase

Rated Maximum

Supply Current

1

1eff

Direct Current

(DC)

Primary Voltage

Degree Of
Protection

Maximum Effective

Supply Current

U

2

2

Alternating

Current (AC)

Gas Metal Arc

Welding (GMAW)

Conventional
Load Voltage

Rated Welding

Current

Suitable for Some

Hazardous

Locations

V

Protective Earth

Three Phase Static

Frequency Con-

X

Voltage

(Ground)

verter-

Transformer-

Rectifier

Duty Cycle

Percent

3-4. Manufacturer ’s Rating Label

229 908-A

OM-230 032 Page 13

SECTION 4 − INSTALLATION

DC

A

(584 mm)

17-3/32 in

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

4-1. Specifications

Max

Input

Power

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

Welding

Output

225 A @

25 V DC,

100%

Duty

Cycle

Voltage

Range

10-44

Wire Feed

Speed

Range**

Standard:

50-1400

ipm

(1.3-35.6 mpm)

Wire

Diameter

Range

.030-.062 in

(0.8-1.6 mm)

Open

Circuit Volt-

age

80

Amperes In­put At Rated
Load Output

60 Hz,

Three-Phase

400V

10.4 7.2

4-2. Dimensions And Weight

Hole Layout Dimensions

A 17-3/32 in (434 mm)

B 17-3/8 i n (441 mm)

C 19-3/32 in (485 mm)

E

22-1/2 in

(572 mm)

Input

kVA

(0.2*)

Input

KW

6.9

(0.04*)

23 in

D 16-3/32 in (409 mm)

E 1/2 in (13 mm)

Weight

112 lb (51 kg) Net

134 lb (61 kg) Ship

B

C

(434 mm)

D

Ref. 803 667-A

OM-230 032 Page 14

4-3. Duty Cycle And Overheating

100% Duty Cycle At 225 Amperes 60% Duty Cycle At 300 Amperes

Duty Cycle is percentage of 10
minutes 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

4-4. Volt-Ampere Curves

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 − 230 226-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

0 100 200 300 400 500 600

AMPERAGE

va_curve1 4/95

OM-230 032 Page 15

4-5. Selecting A Location

Movement

Location

Tipping

2

OR

1

! Special installation may be required where gasoline or volatile

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

4

18 in

(460 mm)

18 in

(460 mm)

! Do not move or operate

unit where it could tip.

! Do not stack units. Beware of

tipping.

1 Lifting Forks

3

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.

4-6. Connection Diagram

3

2

7

8

6

loc_2 3/96 -Ref. 803 667-A

1 Welding Power Source
2 Wire Feeder
3 Gas Cylinder
4 Gas Hose

4

5

1

9

5 Network Feeder Cable
6 Negative (−) Weld Cable
7 Workpiece
8 Voltage Sensing Lead
Recommended for Accu-pulse and

RMD (optional).

. Positive (+) voltage sensing

lead is contained in the motor
cable.

9 Positive (+) Weld Cable

OM-230 032 Page 16

Ref. 803 667-A / Ref. 801 915-A

4-7. Rear Panel Receptacles And Supplementary Protectors

4

1

2

3

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 Network Wire Feeder Receptacle

RC1

Use receptacle to connect network
feeder cable to power source (see
Section 4-6).

Ref. 803 668-A

OM-230 032 Page 17

4-8. Connecting To Weld Terminals

. If using an electrode negative (straight polarity)

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

1

6

3

anything between

weld cable terminal

and copper bar.

2

Do not place

4

Tools Needed:

3/4 in (19 mm)

5

! 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.

Correct Installation

See Section 5-1 to select proper cable size.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Connect positive weld cable to Positive (+ )

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

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

Incorrect Installation

Ref. 803 667-A / 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-230 032 Page 18

4-9. Network Wire Feeder Receptacle Functions

I

G

I

H

A

B

9

*The remaining pins are not used.

F

A

Ref. 803 668-A

Pin* Pin Information

A Not used.

E

D

C

B Shield.
C V olt sense.
D Can low .
E Can high.
F +24 volts dc common.

G + 24 volts dc
H Motor voltage +40 volts dc common

I Motor voltage +40 volts dc

OM-230 032 Page 19

4-10. 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.

Three

Phase

50/60 Hz

Input Voltage 400
Input Amperes At Rated Output 10.4
Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay

Normal Operating 3 15

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

10

14

223
(68)

14

OM-230 032 Page 20

4-11. Connecting Input Power

3

= GND/PE Earth Ground

5

8

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

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

Tools Needed:

2

4

7

3

L1
L2

6

L3

1

Route input conductors

to filter board.

A

s

l

g

k

d

s

A

;

lg

s

l

k

d

s

h

;l

f

d

s

f

g

g

k

k

s

d

;d

s

;

g

lg

l

k

k

A

s

s

;

ld

l

g

k

fg

d

k

s

S

;

;

s

lg

ld

;d

k

k

g

s

g

lk

;l

s

ld

d

f

g

g

k

k

s

s

d

;d

lk

g

s

l

k

;l

d

fg
k

s

;

d

g

l

k

219842−A

5/16 in

Route ground conductor

through tubing and cur-

rent transducer to

ground terminal.

804 650-A / Ref. 803 855-A / Ref. 803 766-A / 219 842-A

! Turn Off welding power source, and

check voltage on input capacitors
according to Section 9-1 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 4-10. Conductors must comply with
national, state, and local electrical codes. If

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

Welding Power Source Input Power
Connections

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

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

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.

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 4-10 (fused disconnect
switch shown).

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

OM-230 032 Page 21

SECTION 5 − RECOMMENDED SETUP PROCEDURES

5-1. Selecting Weld Cable Sizes*

! ARC WELDING can cause Electromagnetic Interference.

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

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

Not Exceeding****

Weld Output

Terminals

! Turn off power before

connecting to weld
output terminals.

! Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

100 ft (30 m) or Less

Welding

Amperes**

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

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 − 100% Duty Cycle

300 ft

(90 m)

350 ft

(105

m)

400 ft

(120

m)

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

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

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)

Positive

)

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

Negative

*

Ref. 803 669-A

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

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 characteris-

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

OM-230 032 Page 22

5-2. Welding Circuit

. Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics.

1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable
5 Voltage Sensing Lead
6 Wire Feeder
7 Workpiece
In pulse welding applications using

inverter power sources, cable
resistance can result in less than
satisfactory performance. In most
cases, a welding circuit length of 50 ft
(15 m) or less will provide satisfactory
performance with a standard welding
circuit connection.

The length of a welding circuit is
determined as follows:

Welding Circuit = Electrode Cable
Length (ECL) + Work Cable Length
(WCL) + Wo rkpi ece Length (WL)

See Section 5-1 for weld cable size.
Variations in welding processes and

welding circuit resistance can affect
apparent voltage at the welding arc.
Voltage sensing can improve welding
performance by providing accurate
feedback to the welding power source.

It is important to connect the voltage
sensing lead as near to the weld as
possible, but not in the return current
path.

Standard Welding Circuit

ECL

7

Large Weld Structure

6

Gun

Travel

WL

1

3

2

4

5

WCL

Current Flow Path

1

3

ECL

6

2

7

WL

2

4

5

WCL

Current Flow Path

Ref. 804 525-A

OM-230 032 Page 23

5-3. Arranging Welding Cables To Reduce Welding Circuit Inductance

1 Welding Power Source
2 Electrode Cable
3 Feeder Cable

Bad

Better

1

2 3

6

5

4

7

1

2

3

4 Work Cable
5 Voltage Sensing Lead
6 Wire Feeder
7 Workpiece
The method used to arrange cables has

a significant affect on welding
properties. As an example, Accupulse
and RMD welding processes can
produce high welding circuit inductance
depending on cable length and
arrangement. This can result in limited
current rise during droplet transfer into
the welding puddle.

The electrode sense lead is contained
in the feeder control cable and
automatically becomes enabled for all
semi-automatic processes. The work
sense lead connects to the Axcess
welding power source 4-pin connector
located above the negative output
terminal. This work sense lead
automatically compensates for work
cable voltage drop when connected to
the welding power source.

Do not coil excess cables. Use cables
that are the appropriate length for the
application. Whenever using long weld
cables [longer than 50 ft (15 m)] try to
arrange positive and negative weld
cables together to reduce the magnetic
field surrounding the cables. Avoid
coupling the feeder and work sense
leads with the weld cables.

Best

6

4

5

7

1

2

3

6

4

5

OM-230 032 Page 24

7

Ref. 804 526-A

. Welding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensify.

5-4. Using Multiple Welding Power Sources

1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable

1

3

2

6

4

5

7

5

Gun

Travel

3

2

6

4

5 Voltage Sensing Lead
6 Wire Feeder
7 Workpiece
Each welding power source should

have a separate work cable connection
to the workpiece. Do not stack or join
work cables together at the workpiece.
This is very important for pulse welding
applications.

It is important to connect the voltage
sensing lead as near to the weld as
possible, but not in the return current
path.

Connect voltage sensing lead at the end
of the weld joint.

The direction of the welding path should
be away from the work cable
connections.

Connect work clamp at the beginning of
the weld joint.

Each welding gun should have its own
source of shielding gas. Use a separate
shielding gas regulator and shielding
gas connection for each welding gun.

Arc blow is the deflection of a welding

1

arc from its normal path due to magnetic
forces. It will adversely affect the
appearance of a weld, cause excessive
spatter, and impair the quality of a weld.
Arc blow occurs primarily during the
welding of steel or ferromagnetic
metals. Weld current will take the path of
least resistance, but not always the
most direct path through the workpiece
to the work lead connection. The most
intense magnet force will be around the
arc due to a difference in resistance for
the magnetic path in the base metal.
The work clamp connection is important
and should be placed at the starting
point of a weld. It is recommended to
have as short of an arc as possible so
that there is less of an arc for the
magnetic forces to control. Conditions
affecting the magnetic force acting on
the arc vary so widely that the reference
here is only about cabling connections
and arc preferences.

Current Flow Path

Ref. 804 527-A

OM-230 032 Page 25

5-5. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs

A. Bad Setup

1

3

2

6

5

1

Current Flow Path

1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable
5 Voltage Sensing Lead
6 Wire Feeder

6

7

7 Workpiece
This arrangement is a bad setup due to

sensing leads being directly in the current
flow path of the welding arc. Interaction
between welding circuits will affect voltage
drop in the workpiece. The voltage drop

3

2

5

4

Ref. 804 528-A

across the workpiece will not be measured
correctly for the voltage feedback signal.
Voltage feedback to the welding power
sources will not be correct at either sense
lead and result in poor arc starts and arc
quality.

OM-230 032 Page 26

B. Better Setup

7

1

3

2

6

4

1

5

3

2

Current Flow Path

1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable
5 Voltage Sensing Lead

6

6 Wire Feeder
7 Workpiece

This arrangement is a better setup for
supporting separate voltage feedback to

4

5

Ref. 804 529-A

the welding power sources. The most
accurate voltage sensing may not be
achieved due to voltage drops in the
workpiece. This may require
compensation in the welding parameters.

OM-230 032 Page 27

C. Best Setup

1

3

2

6

7

Current Flow Path

1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable

4

6

5 Voltage Sensing Lead
6 Wire Feeder
7 Workpiece

5

5

3

2

1

4

Ref. 804 530-A

This arrangement is the best setup for
proper voltage sensing at the workpiece.
Voltage feedback to the welding power
sources will more accurate and result in
reliable arc starts and better arc quality.

OM-230 032 Page 28

SECTION 6 − OPERATION

6-1. Front Panel Switches

2

1 Power Switch
Turns unit On or Off.

1

2 Pilot Light
Light indicates status of welding power

source, on when unit is on and of f when unit is
off.

3 PDA Port
4 PC Port

3
4

Ref. 803 669-A

6-2. Options

A. E-Stop Option

The E-Stop option comes with a 2-pin amphenol receptacle, matching plug, and 30 ft (9 m) of high density molded cord
to allow connecting the welding power source into an E-Stop circuit. An integrator will need to supply a closure for the
non E-Stop condition.

When the E-Stop input connection changes it state from closed to open, the welding power source goes into an E-Stop
mode where all welding outputs shutdown immediately . Once the input connection returns to a closed state, the unit
will start a reset routine and be ready for opeation when it completes the reset operation.

B. DeviceNet Option

The DeviceNet option provides hardware and software that allows the welding power source to be connected into a
DeviceNet network.

Contact factory for option details.

C. RMD Option

RMD (Regulated Metal Deposition) is a precisely controlled short-circuit transfer welding process. Some of the bene­fits provided by the RMD process are the ability to weld thin gauge material and use larger diameter welding wire on
thin gauge material, improved gap filling, reduction of spatter, less heat input into the workpiece, and less distortion.

The RMD process is a software option that is loaded into the welding power source.
Contact factory for option details.

OM-230 032 Page 29

SECTION 7 − MAINTENANCE

Every

3

7-1. 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

7-2. 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. 803 667-A

OM-230 032 Page 30

SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING

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

8-1. Symbol Usage

OM-230 032C - 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 .

8-2. 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

boards or parts.

D Use proper static-proof bags and boxes to

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.

OM-230 032 Page 31

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.

8-3. 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.

8-4. 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:

OM-230 032 Page 32

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.

SECTION 9 − TROUBLESHOOTING

9-1. 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.

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

Remove cover
1 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 inverter
assembly 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.

1

2

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

3

Typical Bleeder Resistor

25 to 1000 ohm, 5

watt resistor

#16 AWG 1000 volts dc
insulation rating, approx

3 in (76 mm) leads

802 985 / Ref. 803 670-A

OM-230 032 Page 33

9-2. Weld Process Board PC4 Diagnostic LED’s

1

1 Weld Process Board PC4
Diagnostic LED’ s are visible inside unit,

located o n PC4 mounted on the top tray.
Refer to Section 9-3 for information on

diagnostic LED’s.
Reinstall cover after checking diagnostic

LED’s.

LED1

LED2

LED3
LED4

9-3. Diagnostic LED’s On Process Board PC4

LED Status Diagnosis

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

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

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

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

3,4 On See Network Status Table in Section 9-4

Off See Network Status Table in Section 9-4

OM-230 032 Page 34

216 956-A / Ref. 803 670-A

9-4. Network And Module Status LED’s

A. Network Status LED’s

The following is a network status LED:
LED4 on the PCM 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 is a module status LED:
LED3 on the PCM circuit board.

Status Diagnosis

Off There i s n o 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-230 032 Page 35

9-5. Troubleshooting

constant current power source.

Trouble Remedy

No weld output; completely inoperative Place line disconnect in On position (see Section 4-11 ).

Check and replace line fuse(s), if necessary, or reset circuit breaker
(see Section 4-11).

Check for proper input power connections (see Section 4-11).

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

Erratic or improper weld output with no
errors displayed.

No 115 volts AC at the duplex
receptacle.

Wire does not feed. Check supplementary protector CB2 and reset if necessary.

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 5-1).

Clean and tighten all weld connections.
Reset supplementary protector CB1.

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-230 032 Page 36

Notes

OM-230 032 Page 37

SECTION 10 − ELECTRICAL DIAGRAMS

OM-230 032 Page 38

Figure 10-1. Circuit Diagram For Welding Power Source

229 810-A

OM-230 032 Page 39

. Hardware is common and

not available unless listed.

SECTION 11 − PARTS LIST

17 − Fig 11-5

1

7

12

13

14

16

15

11

10

9

2

3

4 − Fig 11-3

6 − Fig 11-4

18

20

5 − Fig 11-2

19

19

7

8

OM-230 032 Page 40

Ref. 804 651-A

Figure 11-1. Main Assembly

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

Figure 11-1. Main Assembly

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

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

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

4 Fig 11-3 Top Tray Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 IM-1 214597 Windtunnel, LH w/Components (Fig 11-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IM-1 222958 Windtunnel, RH w/Components (Fig 11-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Fig 11-4 Rear Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 230260 Panel, Side W/Insulator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 210482 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 220200 Assembly, Filter (Primary) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

11 220377 Bracket, Input Filter Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 204846 Insulator, Screw 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC14 185697 Circuit Card Assy, Input Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

15 220376 Bracket, Input Filter Bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 213372 Filter Assy, Secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 Fig 11-5 Front Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

18 010467 Connector, Clamp Cable 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 225840 Washer, Reducer 1.25 in − 0.75 in 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 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.

OM-230 032 Page 41

13

Part

Dia.

Item

ty

12
11

10

14

15

. Hardware is common and

2

3

6

7

32

1

4

5

6

7

8

9

33

34

35

17

18

19

31

30

29

13

27

28

26

20

21

Figure 11-2. Windtunnel Assembly LH And RH

not available unless listed.

16

23

22

23

38

24

37

25

23

36

802 955-A

No.

Mkgs.

No.

Description

Quanti

Figure 11-2. Windtunnel Assembly LH And RH (Fig 11-1 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*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-230 032 Page 42

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

Figure 11-2. Windtunnel Assembly LH And RH (Continued)
(Fig 11-1 Item 6)

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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

36 PC1 216192 Circuit Card Assy, Control (Inverter 400A) 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-230 032 Page 43

. Hardware is common and

Part

Dia.

Item

ty

not available unless listed.

5

6

1

2

3

4

5

7

803 422-B

Figure 11-3. Top Tray Assembly

No.

Mkgs.

No.

Description

Quanti

Figure 11-3. Top Tray Assembly (Fig 11-1 Item 4)

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

2 223439 Insulator, circuit card (Aux Power) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 170647 Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC4 221277 Process Control Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6 210491 Panel, Mtg Components Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 198122 Stand−Off Support, PC Card .250 w/Post&Lock .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-230 032 Page 44

. Hardware is common and

Part

Dia.

Item

ty

not available unless listed.

11

9

10

3

2

1

4

5

6

7

8

Figure 11-4. Rear Panel Assembly

No.

Mkgs.

No.

Description

Quanti

Figure 11-4. Rear Panel Assembly (Fig 11-1 Item 8)

1 210478 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 210358 Eye Bolt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 219929 Nameplate, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 217297 Cover, Receptacle Weatherproof Duplex Rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 210483 Bracket, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

8 RC2 196814 Receptacle, w/Leads (115V Duplex) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC12 209676 Circuit Card Assy, E-Stop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 115440 Stand-off, no 6-32 x .687 lg .250 hex al fem 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 212764 Plug Assy, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 672-A

*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-230 032 Page 45

. Hardware is common and

Part

Dia.

Item

ty

not available unless listed.

16

17

18

12

2

3

4

10

8

9

11

6

6

21

5

7

20

19

7

6

1

13

15

15

14

Figure 11-5. Front Panel Assembly

No.

Mkgs.

No.

Description

Figure 11-5. Front Panel Assembly (Fig 11-1 Item 14)

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

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

3 211475 Plate, front panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5 FM 196313 Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7 213102 Choke, Common Mode w/Leads 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 216965 Cover, Connector D-sub 9 skt Female w/Chain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

11 210866 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 210476 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 219843 Label, Volt Sense (wordless) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ref. 804 676-A

Quanti

OM-230 032 Page 46

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

Figure 11-5. Front Panel Assembly (Continued)

14 207979 Box, Louver 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 186621 Boot, Generic 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 PL1 163562 Light, ind white lens 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 212777 Nameplate, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 210865 Terminal, Pwr Output Red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 210483 Bracket, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 210358 Bolt, eye shld thd stem .500−13 X 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 207980 Bus Bar, output 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-230 032 Page 47

Notes

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 Headquarters− USA

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

European Headquarters −
United Kingdom

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