Miller Electric Axcess AlumaFeed 75 User Manual

OM-228 956B 2006−08

Processes

MIG (GMAW) Welding

Description

Wire Feeder

Axcess AlumaFeed 75

Visit our website at

www.MillerWelds.com

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 2005−04

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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Information EMF 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INTRODUCTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Selecting A Location 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Connection Diagram 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Rear Panel Connections And Rotating Drive Assembly 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. 9-Pin Network Receptacle Information 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Installing Drive Rolls 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Installing PD Continuous Wire Guides 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Installing Non-PD (Old Style) Wire Guides 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Installing Welding Gun 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Installing Welding Wire And Adjusting Pressure Drive Setting 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Feeder Display At Power Up 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Dual Schedule Switch Options 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Operational Terms 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Power Switch 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Front Panel Controls 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Program Push Button 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Upper Display 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Lower Display 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Feeder Set Up Push Button 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Adjust Control 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Process Set Up Push Button 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Jog/Purge 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Reset Mode 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − SETTING SEQUENCE PARAMETERS 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Sequence Parameters In A Program 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Diagnostics 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Troubleshooting 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

som _3/05

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y 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.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y 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 DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

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

D Properly install and ground this equipment according to its

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

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 Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

power circuit and machine internal circuits are also

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

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.

FUMES AND GASES can be hazardous.

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

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

arc to remove welding fumes and gases.

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.

OM-228 956 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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.

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

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

D Do not use welder to thaw frozen pipes.
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 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

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

workpiece, and hot equipment can cause fires and

FLYING METAL 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.

D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

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.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.
D Wearers should consult their doctor before

going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

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 num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

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

OM-228 956 Page 2

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.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can 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 Miller/Hobart replacement

parts.

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.

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.

1-4. California Proposition 65 Warnings

Y 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.)

Y 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.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

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

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

For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive
harm.

For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

OM-228 956 Page 3

1-5. Principal Safety Standards

Safety in Welding, 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, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web­site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic 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:

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
ternational.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd 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, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000, 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 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220, website: www.osha.gov).

1. Keep cables close together by twisting or taping them.

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 Pacemakers:

Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.

OM-228 956 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

Symbole graphique d’avertissement ! Attention ! Cette pro­cédure comporte des risques possibles ! Les dangers éven­tuels sont représentés par les symboles graphiques joints.

som _3/05

Y Indique un message de sécurité particulier

. Signifie NOTE ; n’est pas relatif à la sécurité.

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

Y Les symboles représentés ci-dessous sont utilisés dans ce manuel

pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions en
matière de sécurité indiquées ci-dessous ne constituent qu’un
sommaire des instructions de sécurité plus complètes fournies
dans les normes de sécurité énumérées dans la Section 2-5. Lire et
observer toutes les normes de sécurité.

Y Seul un personnel qualifié est autorisé à installer, faire fonction-

ner, entretenir et réparer cet appareil.

Y Pendant le fonctionnement, maintenir à distance toutes les per-

sonnes, 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
couper ou le sol.

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

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

D Se servir d’une source électrique à courant électrique UNIQUEMENT si

le procédé de soudage le demande.

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

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

D D’autres consignes de sécurité sont nécessaires dans les conditions

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

D Couper l’alimentation ou arrêter le moteur avant de procéder

à l’installation, 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 convenablement

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 conducteur

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

sous tension lorsque le courant est délivré à la

Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.

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 insuffisante

ou mal épissés.

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

câble distinct.

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

ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines en

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

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

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

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

place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-métal

avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.

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

avec tout objet métallique.

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

une même borne de sortie de soudage.

Il reste une TENSION DC NON NÉGLIGEABLE dans
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.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour la santé.

D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-

peurs.

D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de

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

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

vé.

D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et

les instructions du fabricant concernant les métaux, les 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 dé-

graissage, 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 gal-

vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
portant un respirateur à alimentation d’air. Les revêtements et tous les
métaux renfermant ces éléments peuvent dégager des fumées toxi­ques en cas de soudage.

OM-228 956 Page 5

LES RAYONS D’ARC peuvent entraî­ner des brûlures aux yeux et à la peau.

Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-

Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants ap-

proprié 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 vo-

tre 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 résistantes

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

quer des brûlures dans les yeux et sur la peau.

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent

d’étincelles, des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe ou un incendie. Avant de commencer
le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.

D Déplacer toutes les substances inflammables à une distance de

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

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

des substances inflammables.

D Se protéger, ainsi que toute autre personne travaillant sur les lieux,

contre les étincelles et le 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 Afin d’éliminer tout risque de feu, être vigilant et garder toujours un

extincteur à la portée de main.

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

peut déclencher un incendie de l’autre côté.

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

réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa­rés correctement conformément à AWS F4.1 (voir les normes de
sécurité).

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

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

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

gelées.

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

électrode ou couper le fil à la pointe de contact.

D Porter des vêtements de protection exempts d’huile tels que des

gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.

D Avant de souder, retirer toute substance combustible de ses poches

telles qu’un allumeur au butane ou des allumettes.

D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B

pour travaux de soudage et prévoir un détecteur d’incendie et un ex­tincteur à proximité.

être projetées de l’arc de soudure. La projection

DES PARTICULES VOLANTES
peuvent blesser 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

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

facial.

de projeter du laitier.

LES ACCUMULATIONS DE GAZ
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.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

D Ne pas toucher des parties chaudes à mains

nues.

D Prévoir une période de refroidissement avant

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

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

d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent

affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, rester

à distance.

D Les porteurs d’un stimulateur cardiaque doi-

vent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc,
de gougeage ou de soudage par points.

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
gaz font normalement partie du procédé de soudage,

les manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessi-

ve, 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 sta-

tionnaire 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 lors-

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

D Utiliser les équipements corrects, les bonnes procédures et suf-

fisamment 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.

OM-228 956 Page 6

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

Risque D’INCENDIE OU D’EXPLO­SION.

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

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de

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

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

produits inflammables.

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

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.

suffisante pour lever l’appareil.

L’EMPLOI EXCESSIF peut SUR­CHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ;

respecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistati-

ques pour stocker, déplacer ou expédier des
cartes PC.

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.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres

personnes ou toute pièce mécanique en enga­geant le fil de soudage.

DES ORGANES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de

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.

protection.

LIRE LES INSTRUCTIONS.

D Lire le manuel d’utilisation avant d’utiliser ou

d’intervenir sur l’appareil.

D Utiliser uniquement des pièces de rechange

Miller/Hobart.

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

D Le rayonnement haute fréquence (HF) peut

provoquer des interférences avec les équipe­ments de radio-navigation et de communica-

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 électri-

cien qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

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

tion, les services de sécurité et les ordinateurs.

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

D L’énergie électromagnétique peut gêner le

fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.

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

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.

soudage soit compatible électromagnétiquement.

2-4. Proposition californienne 65 Avertissements

Y Les équipements de soudage et de coupage produisent des

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

Y 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 :
Y 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.

Pour les moteurs diesel :
Y 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-228 956 Page 7

2-5. Principales normes de sécurité

Safety in Welding, 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, 1 Battery March Park, 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, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, Standards Sales, 178 Rexdale

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 :

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
800-463-6727 ou à Toronto 416-747-4044, site Internet :
www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd 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, 1 Battery March Park, 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 (il y a 10
bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).

1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.

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 stimulateurs cardiaques

Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le méde­cin approuve, il est recommandé de suivre les procédures précédentes.

OM-228 956 Page 8

3-1. Specifications

SECTION 3 − INTRODUCTION

Type of Input

Power

40 Volts DC
10 Amperes

Welding Power

Source Type

Axcess Series Standard: 40 To 1400 ipm (1.0

Wire Feed Speed Range

SECTION 4 − INSTALLATION

4-1. Selecting A Location

Movement

To 35.6 mpm)

OR

1

Wire Diameter

Range

.045 To .062 in

(1.1 To 1.6 mm)

Max Spool

Weight: 60 lb (27

kg)

Tipping

2

Welding Circuit

Rating

100 Volts,

750 Amperes,

100% Duty

Cycle

Y Do not move or operate

Overall

Dimensions

Length: 27 in (686

mm)

Width: 12-1/2 in

(318 mm)

Height: 14-1/2 in

(368 mm)

unit where it could tip.

Weight

70.5 lb

(32.0 kg)

Location

3

Y 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)

Y Do not stack units. Beware of

tipping.

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

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

unit.
3 Rating Label
Use rating label to determine input

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

power supply.

loc_2 3/96 - Ref. 804 585-A

OM-228 956 Page 9

4-2. Connection Diagram

3

2

7

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

4

5 Network Feeder Cable
6 Negative (−) Weld Cable
7 Workpiece
8 Voltage Sensing Lead

(Optional)

. Positive (+) voltage sensing

5

1

lead is contained in the motor
cable.

9 Positive (+) Weld Cable

8

6

9

Ref. 801 915 / Ref. 804 584-A

OM-228 956 Page 10

4-3. Rear Panel Connections And Rotating Drive Assembly

7

1

2

350 Amps and above

weld connection

1 9-Pin Network Receptacle
2 Shielding Gas Valve Fitting
Requires fitting with 5/8-18 right-

hand threads. Connect customer­supplied gas hose.

3 Weld Cable
4 Weld Cable Screw - Screw

Size (.375 - 16 x 1.50)
5 Drive Assembly
6 Drive Assembly Rotation

Knob
7 Rating Label Location
To rotate the drive assembly, loos-

en drive assembly rotation knob,
rotate drive assembly, and tighten
knob.

3

0 to 350 Amps

weld connection

5

6

4

Tools Needed:

9/16, 5/8 in
3/16 in

804 586-A

OM-228 956 Page 11

4-4. 9-Pin Network Receptacle Information

F

E

I

D

C

9

E

G

H

I

A

B

Pin Pin Information

A Capacitor C1 to ground
B Shield
C Volt sense
D Can low
E Can high
F +24 volts dc common

G + 24 volts dc
H Motor voltage −40 volts

I Motor voltage +40 volts

4-5. Installing Drive Rolls

4

3

2

1

1 Pressure Assembly Door
2 Drive Roll
3 Ejector Button
4 Drive Roll Carrier

Installation

Open pressure assembly door.
Align drive roll slots with three lobes

on drive roll carrier.
Insert drive roll onto carrier. Drive

roll will snap into place.

Removal

. Remove PD wire guide before

removing lower drive rolls.

Lift up drive roll swing arm and
press ejector button in middle of
drive roll carrier.

. If ejector button does not re-

turn to normal position (out),
install a drive roll and ejector
button will pop out.

OM-228 956 Page 12

804 187-A

4-6. Installing PD Continuous Wire Guides

3

4

2

1

. PD Continuous Wire Guides:

Should be used with
.068/.072 in (1.8 mm) and
smaller diameter wire for opti­mal performance.

Should be used with PD
drive rolls and cannot be used
with non-PD (old-style) drive
rolls.

. 70 series wire guides are not

compatible with 75 series wire
feeders.

1 Pressure Assembly Door
2 PD Inlet Guide
3 PD Wire Guide (Hard Wire)
4 PD Wire Guide (Two Pieces

interlocked for Aluminum
Wire)

Installing PD continuous wire
guides with PD drive rolls.

. Drive rolls are identified by the

initials PD and a part number
on the drive roll.

Open pressure assembly door.
Lift up drive roll swing arms.
Remove PD inlet guide.
Insert wire guide gun end (indi-

cated with arrow) into block near
brass power pin gun connector.

Install PD inlet guide.

. Do not tighten set screw to se-

cure inlet guide.

. Set screw may be used to se-

cure PD inlet guide replace­ments such as wire straighten­ers or conduit adapters.

Ref. 804 192 / 804 188-A

OM-228 956 Page 13

4-7. Installing Non-PD (Old Style) Wire Guides

5

2

3

4

1

Tools Needed:

Installing wire guides with non­PD (old-style) drive rolls

. Non-PD (old-style) wire guides

and drive rolls should be used
with 5/64 in (2.0 mm) and larger
diameter wire.

1 Pressure Assembly Door
2 PD Inlet Guide
3 Intermediate Guide
4 Set Screw
5 Guide Holder

6

6 Exit Guide
Open pressure assembly door.
Lift up drive roll swing arms.
Install PD inlet guide.

. Do not tighten set screw to se-

cure inlet guide.

. Set screw may be used to se-

cure PD inlet guide replace­ments such as wire straighten­ers or conduit adapters.

Remove screw securing intermedi­ate guide holder. (Guide holder is
located between the lower front
and rear drive roll carriers.)

Rotate guide holder 180 degrees
and reinstall.

Install intermediate guide into guide
holder and tighten set screw.

Loosen set screw, insert exit guide
into block near brass power pin gun
connection and secure with set
screw.

. When using smaller diameter

inlet guide (219108) with non­PD (old style) drive rolls, a 1/4
in (6 mm) gap will be present
between the guide and drive
roll.

OM-228 956 Page 14

1/16, 1/8, 5/32 in

Ref. 804 192-B / 804 188-A

4-8. Installing Welding Gun

1 Power Clamp Knob
2 Gun Locking Tab
3 Power Pin Groove
4 Gun Connection End

Installing gun with Accu-Mate
connection

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

When installing gun, the liner
should extend into the PD continu­ous guide (or exit guide if used) as
far as possible without interfering
with the guide.

Align the groove in the power pin of
the gun with the gun locking tab.

4

3

Secure gun by tightening power
clamp knob.

Installing gun without Accu­Mate connection

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

When installing gun, the liner
should extend into the PD continu­ous guide (or exit guide if used) as
far as possible without interfering
with the guide.

Secure gun by tightening power
clamp knob.

Installing gun with

Accu-Mate connection

1

Installing gun without

Accu-Mate connection

2

1

2

804 189-A

OM-228 956 Page 15

4-9. Installing Welding Wire And Adjusting Pressure Drive Setting

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

Thread wire.

. Pressure assembly

door not shown.

No Wire Slip

NONCONDUCTIVE

SURFACE

Drive Rolls

Wire Slips

NONCONDUCTIVE

SURFACE

Back Of Gun

End Of Liner

Adjust tension.

1

2

Ref. 804 190-A

Tools Needed:

15/16 in

1 Drive Roll Pressure Adjustment Lever
2 Notch In Lever (Indicates Pressure

Settings)

Pressure drive settings range from 1 to 8 with
8 being the maximum setting.

. For aluminum (soft) wire set pressure

drive setting at 4 or below.

. Be sure that gun has proper size liner for

the welding wire size.

OM-228 956 Page 16

When installing gun, the liner should extend
into the PD continuous guide (or exit guide if
used) as far as possible without interfering
with the guide.

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

To adjust drive roll pressure, hold nozzle
about 2 in (51 mm) from nonconductive

surface and press gun trigger to feed wire
against surface. Adjust pressure drive lever
so wire does not slip. Do not overtighten. If
contact tip is completely blocked, wire should
slip at the feeder (see pressure adjustment
above.)

Cut wire off.

4-10. Feeder Display At Power Up

1

Program

Process
Wire Type
Gas Type

Process Set Up Feeder Set Up

Power Source

Volts Time

WFS Amps

Adjust

Upper Display

Arc Adjust

Arc Ctl

Lower Display

Sequence
Trigger Control
Trigger Hold

2

Voltage Range

Axcess Axcs 300/450/675 10 44

1 Upper Display
2 Lower Display

4-11. Dual Schedule Switch Options

11

DSS-9M

22

3A

4B

1 Maint 2P (Maintained-Contact

2-Pole Switch)

DSS-9M Part# 041 793

1

OM-228 956 Page 17

SECTION 5 − OPERATION

5-1. Operational Terms

The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:

General Terms:
Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases

Trigger Control Selecting Trigger Control allows activating trigger functions such as DS, TH, 4T, TDS, and TPS.
DS (Dual Schedule) Dual Schedule allows selecting a pair of programs that can be used together.
TH (Trigger Hold) Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger. In trigger

4T 4T allows the operator to select between weld parameters and crater parameters using the gun

TDS (Trigger Dual Schedule) TDS allows the operator to select between a pair of weld programs by using the gun trigger. In TDS

TPS (Trigger Program Schedule) TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily

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

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

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

Wire Type Selection of wire type by alloys and classification.
Gas Type Selection of shielding gas being used in application.
Process Set Up Selection procedure for entering program.
Program Load Enters selected program information into program slot.
Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of

Time Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in

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

Amps Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Control Allows setting of inductance in MIG mode. In pulse and Accu-pulse mode, this adjustment changes

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

Adjust Control knob used to change or set parameters and functions.
Sequence Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters.
Preflow Setting a time value for gas flow prior to arc start.
Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only

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

hold mode, momentarily press gun trigger, and wire will feed until gun trigger is momentarily pressed
again.

trigger. Crater time must be set for at least 0.2 seconds to make this function operational. If gun
trigger is released during welding, unit goes into trigger hold, then pressing and holding trigger again
causes unit to stay in crater until trigger is released and crater parameter times out.

mode, momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected
weld programs.

pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total
of 8 programs.

factory taught data. Adaptive method is controlled by frequency adjustment.

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

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

weld.

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

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

the arc cone by adjusting the preprogrammed factory pulse data. In RMD (optional), this control will
affect the in much the same way as inductance.

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

adjustable with the optional PDA with File Management/WaveWriter software).

OM-228 956 Page 18

General Terms:
Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends.
Postflow Setting a time value for gas flow after arc end.
Feeder Set Up Allow selection of Sequence and trigger functions.
Auto Thread Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously

will automatically feed wire. Default setting is 192 at a feed rate of 700 ipm (these values can be
changed using a PDA with File Management/WaveWriter software). Pressing jog, purge, or trigger
switch will terminate the auto-threading feature.

5-2. Power Switch

1 Power Switch

1

804 587-A

OM-228 956 Page 19

5-3. Front Panel Controls

See

Section

5-4

Program

Volts Time

Arc Adjust

See

Section

5-5

See

Section

5-6

WFS Amps

Process
Wire Type
Gas Type

Process Set Up Feeder Set Up

See

Section

5-9

Adjust

See

Section

5-8

Arc Ctl

Sequence
Trigger Control
Trigger Hold

See

Section

5-7

OM-228 956 Page 20

5-4. Program Push Button

1

2

Program

1 Program Display
The number of the active program

is displayed.
2 Program Push Button
3 Program Push Button LED
The LED lights to indicate that

programs can be changed using
the Adjust knob.

Momentarily press button to
illuminate LED. To change the

3

program number, rotate Adjust knob
to select one of eight programs.

Pressing and holding the push
button will display current wire size,
wire type and process.

To reset feeder to factory settings,
turn power source off for 10
seconds. Press and hold button in
on power up, wait until top display
shows RST and bottom display
shows NO before releasing button.
Feeder Set Up button LED will
begin flashing. Turn Adjust knob to
change bottom display to show
YES, then press Feeder Set Up
button to confirm selection. The top
display will show CYCL and the
lower display will show PWR. Turn
welding power source power off for
10 seconds, then turn power back
on again.

5-5. Upper Display

1

4

1 Upper Display
The upper display shows voltage or arc

length. The unit displays both preset voltage
or arc length and actual voltage. When
welding, actual arc voltage is displayed.

2 Upper Display Push Button
Press the button to illuminate the LED and

allow changing information in the display.
Release button to display voltage.

3 Upper Display Push Button LED
The upper display push button LED

Volts Arc Adjust

5

illuminates to indicate that information
displayed can be changed by the Adjust
control.

4 Volts LED (Weld Voltage In MIG)
5 Arc Adjust LED (Pulse Mode)
The LEDs below the display illuminate to

indicate which value is being shown.
At any time while welding, the unit permits the

adjustment of the weld voltage and overrides
the display of actual arc voltage.

3

2

To activate Carbon Arc Cutting (CAC), press
and hold the upper display push button in on
power up. CAC will appear on the upper
display and NO will appear on the lower
display. Rotate adjust knob to YES on the
lower display, and press the flashing Feeder
Set up push button . CYCL will appear on the
upper display and PWR will appear on the
lower display. Turn welding power source off
and back on again to enable the Carbon Arc
Cutting process selection.

OM-228 956 Page 21

5-6. Lower Display

7

Time

3

1

4

1 Lower Display

The lower display shows WFS (wire feed
speed), AMPS (amperage), ARC CTL (arc
control), or Time. The feeder displays only
preset wire speed at idle (not welding). While
welding, the average amperage is displayed.
The lower display shows welding sequence
time when the Time LED is illuminated.

2 WFS (Wire Feed Speed) LED

LED illuminates to indicate the preset wire feed
value is being displayed and can be adjusted
using the Adjust knob.

3 Amps LED

LED illuminates to indicate the average
amperage is being displayed while welding
and for 3 seconds after welding is terminated.
The amperage must be above a minimum
value of 25 amps for this function to operate.

WFS Amps Arc Ctl

5

4 Arc Ctl (Arc Control) LED
LED illuminates to indicate that inductance

(MIG) or ARC [Pulse, Accu-pulse, or RMD
(optional)] is being displayed and can be
adjusted using the Adjust knob.

5 Time LED
LED illuminates to indicate that a time value is

being displayed for a sequence function and
can be adjusted using the Adjust knob.

6 Lower Display Push Button
7 Lower Display Push Button LED
Pressing the button illuminates the LED and

selects either WFS or Arc Ctl value for
changing using the Adjust knob.

To select Arc Ctl, press and hold lower display
button for 2 seconds. The top display will show
either INDU for a MIG program or ARC for
Pulse, Accu-pulse, or RMD (optional). To exit
Arc Ctl or INDU, either press the upper display
push button or press and hold the lower display
push button for 2 seconds.

6

2

During a welding program operation, it is
possible to change WFS (wire feed speed) by
using the Adjust knob regardless of the active
program sequence that appears on the dis­play.

When the Arc Ctl LED is illuminated, it is
possible to change values while welding by
using the Adjust knob. To return to actual
values on the display, exit the Arc Ctl display.

. The lower display push button has

additional functions when entering the
sequence and trigger control functions
(see Section 5-7).

OM-228 956 Page 22

5-7. Feeder Set Up Push Button

3
4
5

1

Sequence
Trigger Control
Trigger Hold

Feeder Set Up

Start
Time

2

6

Preflow

Time

Welding Sequence Diagram

Weld
Time

Crater

Time

Postflow

Time

1 Feeder Set Up Push Button
2 Feeder Set Up Push Button LED
Press button to choose sequence, trigger

control, or trigger hold.
3 Sequence LED
4 Trigger Control LED
5 Trigger Hold LED
6 Lock LED (Access Allowed Only By

Using An Optional PDA With File
Management Software)

• When the Feeder Set Up button is pressed

while in standby, the Feeder Set Up push
button LED illuminates and the top display
will be active. Use the Adjust control to
select preflow (PRE), start (STRT), crater
(CRTR), or postflow (POST) parameters.

• Press the lower display push button to allow

the bottom display to become active. The
time LED will automatically begin flashing

5-8. Adjust Control

and the unit will be in the time mode. Initially,
all sequences will appear as off. Use the
Adjust control display time and enable the
time sequence. Setting a time automatically
enables a sequence. To turn off a sequence,
change time setting to OFF.

• If the sequence has a voltage or arc adjust

setting, pressing the lower display push
button a second time will cause either volts
or arc adjust to appear on the display. Use
the Adjust control to set either parameter.

• If the sequence has a wire feed setting,

pressing the lower display push button a
third time will cause wfs to appear on the
display. Use the Adjust control to set wire
speed parameter.

• Press the lower display push button a fourth

time will cycle the display back to time.

• Press the Feeder Set Up button a second

time to go to Trigger Control mode and allow

1

the top display to become active. Use the
Adjust control to cycle through trigger
control methods as follows: dual schedule,
trigger hold, trigger dual schedule, program
select, 4T (see Section 5-1). The lower
display will show the current state of each
trigger control method as being either on or
off. Not all trigger control methods are
compatible with each other, and turning on
certain functions will cause other trigger
functions to turn off.

• Press the lower display push button to allow

the bottom display to become active. Use
the Adjust control to turn selected trigger
control methods on or off. If trigger hold is
set to on, the trigger hold LED will illuminate.
Note: if 4T is set to on, trigger hold will
automatically be set to on since this
parameter is necessary for the 4T function.

• Press the Feeder Set Up button a third time

to cycle back to standby mode.

1 Adjust Control
The Adjust control is used to

change various sequence parame­ters, and to select various se­quences. Refer to the section for
the function in question for informa­tion related to using the Adjust con­trol.

Adjust

OM-228 956 Page 23

5-9. Process Set Up Push Button

3

Process
Wire Type
Gas Type

Process Set Up

1 Process Set Up Push Button
2 Process Set Up LED
3 Program Selection LEDs

2

1

• Press the Process Set Up push button the

first time will illuminate the button LED and
Process LED above the button. Both
displays will show the current process and,
if desired, these displays will be active to
allow selecting a new process. Default
processes are MIG, PULSE, and ACCU
PULSE.

• Pressing the Process Set Up push button a

second time will illuminate the Wire Type
LED and the bottom display will show wire
types available for the selected process. To
make a selection, rotate the Adjust control.

• Pressing the Process Set Up push button a

third time will keep Wire Type LED lit, but the
upper display will be active and show wire
sizes available for the current wire type. To

make a selection, rotate the Adjust control.

• Pressing the Process Set Up push button a

fourth time will illuminate the Gas Type LED
and both displays will show available gas
selections for the process, and wire type
and wire size selection. To select an item,
rotate the Adjust control.

• Pressing the Process Set Up push button a

fifth time will load the program that matches
the selected parameters (process, wire
type, wire size, gas). The upper display will
show PROG and the lower display will show
LOAD.

If no changes were made to any setup items,
no program will be loaded, and unit will return
to standby mode.

If a custom program is loaded using an
optional PDA with File Management software,
the upper display will show CUST and the
lower display will show PROG. The Adjust
control remains active to allow loading a
standard program in place of the custom
program.

• Pressing and holding the Process Set Up

push button in on power up allows viewing
the software revisions of each circuit board
in the system. The top display shows the
board (PCM, UIM, WFCM, and AIM (auto­mated units only) and the lower display
shows the last 3 digits of the circuit board
part number plus a letter designator. Press
the flashing Feeder Set Up push button to
exit the screen displays and continue the
power up process.

Table 5-1. Welding Wire And Gas Abbreviations*

Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation

Steel STL E70, E100, E120 100% CO2,

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

95% Argon/5% CO2,

95% Argon /5% O2,

98% Argon/2% O

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

(81Ar/18HE/1CO

2

2

2

CO2

C10
C15
C25

C5
OX5
OX2

OX2

Tri Gas

Accu-pulse)

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

2

Tri Gas

MIG/RMD/Accu-pulse)

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

439

90% Argon/10% CO

98% Argon/2% O

2

2

Aluminum ALUM 4XXX, 5XXX 100% Argon ARGN

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

OM-228 956 Page 24

C10

OX2

5-10. Jog/Purge

2

1 Jog/Purge Push Button
2 Adjust Control
3 Gun Trigger Receptacle

3

1

803 505-A

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

• The unit provides the ability to jog the wire

feeder by means of the gun trigger or the
Jog/Purge switch. If the welding arc does
not initiate in 3 seconds after the gun trigger
is activated, the unit will perform a jog
operation for a maximum of 30 seconds. If
the gun trigger is still activated after 30
seconds, the jog operation is terminated to
prevent complete unspooling of the wire, in
the case of a damaged gun. The unit

displays the “ERR STRT“ message to
inform the operator that the trigger is
activated.

• Jog speed can be adjusted by the Adjust

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

• Jogging can also be accomplished by

pressing the Jog/Purge button.

• Pressing the Jog/Purge button also allows

the operator to purge gas lines before

welding and to preset gas pressure at the
regulator.

• This unit is equipped with Auto Thread

capability. By rocking the switch from purge
to jog within 0.5 seconds will automatically
feed wire for a factory default setting of 192
in (4877 mm) of wire before stopping. The
default feed rate is 700 ipm. These settings
can be changed using an optional PDA with
File Management software. Pressing the
Jog/Purge switch or gun trigger during Auto
Threading will terminate the automatic feed
operation.

OM-228 956 Page 25

5-11. Reset Mode

Program

Process
Wire Type
Gas Type

RST

Volts Time Arc Adjust

NO

WFS Amps Arc Ctl

Sequence
Trigger Control
Trigger Hold

. Reset mode is not active when

Program Lock is enabled.

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

. System configuration data will be

lost during the Reset operation.

Enter reset mode by turning power On and pressing

the Program Push Button until the RST NO message

is displayed. RST NO message will not display until

after the power-up sequence is completed

(approximately 20 seconds).

Process
Wire Type
Gas Type

RST

Volts Time Arc Adjust

YES

WFS Amps Arc Ctl

Adjust Feeder Set Up

Sequence
Trigger Control
Trigger Hold

Program

Process
Wire Type
Gas Type

Process Set up

Program

Process Set up

Rotate Adjust knob to change NO

to YES.

The reset message is displayed for

During the reset mode the following

factory default programs are loaded

Program 1 Pulse

Program 2 MIG

Program 3 Accu-pulse

Program 4 Pulse

Program 5 MIG

Program 6 Accu-pulse

Program 7 Pulse

Program 8 MIG

Process Set up

RST

Volts Time Arc Adjust

YES

WFS Amps Arc Ctl

Adjust Feeder Set Up

Sequence
Trigger Control
Trigger Hold

Adjust Feeder Set Up

Press the Arc Control button to

confirm the reset.

2 seconds while factory program

settings are being reloaded.

into the unit:

.035 Mild Steel
90% Argon, 10% CO

.035 Mild Steel
75% Argon, 25% CO

.035 Mild Steel
90% Argon, 10% O2

.045 Mild Steel
90% Argon, 10% CO

.045 Mild Steel
75% Argon, 25% CO

.045 Mild Steel
90% Argon, 10% O2

.052 Mild Steel
90% Argon, 10% CO

.052 Mild Steel
75% Argon, 25% CO

Process
Wire Type
Gas Type

CYCL

Volts Time Arc Adjust

PWR

WFS Amps Arc Ctl

Adjust Feeder Set Up

Program

Process Set up

Cycl Pwr message appears on the display

when programs complete loading.

Turn power off, wait 10 seconds, and turn

power back on again to complete the reset

operation.

. After Reset is complete, be sure to load

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

2

2

2

2

2

2

198 993 / 804 587-A

Sequence
Trigger Control
Trigger Hold

OM-228 956 Page 26

SECTION 6 − SETTING SEQUENCE PARAMETERS

6-1. Sequence Parameters In A Program

Sequence Parameters

Volts/Trim IPM Seconds

1. Preflow Off-5.0

2. Postflow Off-5.0

. For more information on

Sequence mode, see Feeder
Set Up Push Button in Section
5-7.

If time is set to Off in Weld
sequence, welding continues until
gun trigger is released.

If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.

. Maximum IPM may actually

be lower depending on wire
size and gas combination.

3. Start

4. Crater

X = Setting available.

10.0-44.0/
0-99

10.0-44.0/
0-99

Weld

40-1400/
0-99

40-1400/
0-99

Off-5.0

Off-5.0

Crater

Time

Preflow

Trigger

Pressed

Preflow

Time

Start

Start
Time

Weld

Trigger

Released

PostflowCrater

Postflow

Time

Sequence

Time

End

OM-228 956 Page 27

SECTION 7 − MAINTENANCE

E

7-1. Routine Maintenance

Y Disconnect power before maintaining.

very

3

Months

Every
6
Months

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

l Unreadable Labels ~ Weld Terminals nl Weld Cables l Cracked Parts

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

Or

~ Inside Of Unit ~ Drive Rolls

Reference

OM-228 956 Page 28

7-2. Diagnostics

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

ERR

SENS

Indicates a voltage
sense error.

ERR

FLOW

Indicates a gas
flow error.

ERR SENS

• The voltage sense error indicates no

voltage sensing feedback signal. Check
connections at feeder and welding power
source. Press Jog/Purge button to clear
error.

ERR TACH

• The tach error occurs 2 seconds after the

loss of tachometer feedback. The motor
speed is regulated through the monitoring of
voltage and current. Press Jog/Purge
button to clear error.

ERR MOTR

• The motor error indicates that the motor

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

ERR WFS

• The wire feed speed error indicates actual

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

ERR

TACH

Indicates a
tachometer error.

ERR

COOL

Indicates a coolant
flow error.

ERR

MOTR

Indicates a motor
error.

ERR

FTP

Indicates a file
transfer point error.

ERR STRT

• The start error occurs if the user has the

trigger held for more than two minutes
without striking an arc, or if the user holds
the trigger past the postflow phase in a
timed weld. This error also occurs if the
trigger is held when the feeder is powered
up. The error may be cleared by releasing
the trigger, and pressing the Jog/Purge
button.

ERR STOP

• The stop error occurs as result of

obstructions in the wire feed system or a
faulty wire drive system. Check wire feed
and wire drive systems. Press Jog/Purge
button to clear error.

ERR FLOW

• The flow error indicates no gas flow to the

gun. The error may be reset by
reestablishing gas flow to the gun, and then
pressing the Jog/Purge button.

ERR COOL

• The cool error indicates no coolant flow in

water flow switch option. The error may be
reset by reestablishing coolant flow to the
gun, and then pressing the Jog/Purge
button.

ERR

WFS

Indicates a wire
feed speed error.

ERR

GND

Indicates a ground
current error.

ERR

STRT

Indicates an arc
start error.

ERR

STUK

Indicates a wire
stuck error.

ERR FTP

• The file transfer error occurs if data does

not transfer to the feeder correctly. Press
Jog/Purge button to clear error, and transfer
data to feeder again.

ERR GND

• The ground current error occurs if weld

current is detected in the earth ground
connection. May be caused by a conductor
making contact with unit chassis. Check
and repair feeder weld connections. Press
Jog/Purge button to clear error.

ERR STUK

• The stuck error occurs if the welding wire

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

ERR PSF

• The primary power error occurs if the

primary power circuit inside the feeder is not
functioning correctly. Check feeder
connections. Press Jog/Purge button to
clear error.

ERR

STOP

Indicates an arc
stop error.

ERR

PSF

Indicates a primary
power error.

OM-228 956 Page 29

7-2. Diagnostics (Continued)

ERR

TEMP

Indicates a
temperature error.

MOTR

MEM

Indicates a memory
CRC motor error.

ERR TEMP

• The temperature error indicates welding

power source has overheated and
shutdown. The error may be cleared by
allowing unit to cool down, and pressing the
Jog/Purge button.

ERR LINE

• The line error indicates input power is

outside of unit operating range. Check and
correct input power. Press Jog/Purge
button to clear error.

ERR ARC

• The arc error indicates an arc outage

occurred possibly from a wire feeder error
or power source error. Check wire feeder
and power source. Press Jog/Purge button
to clear error.

ERR

LINE

Indicates a line
error.

WELD

WAIT

Indicates a weld
cycle wait error.

ERR

ARC

Indicates an arc
error.

MOTR

COM

Indicates a motor
communication error.

ERR POL

• The polarity error indicates the polarity is

different than the selected polarity. Check
and correct weld cable connections. Press
Jog/Purge button to clear error.

UNIT MEM

• The unit memory error indicates the PCM

board lost memory data. Press Jog/Purge
button to clear error.

UIM MEM

• The uim memory error indicates user

interface board lost memory data. Press
Jog/Purge button to clear error.

MOTR MEM

• The motor memory error indicates motor

board lost memory data. Press Jog/Purge
button to clear error.

WELD WAIT

• The weld wait error indicates unit was not

ready for a weld sequence. Press Jog/
Purge button to clear error.

ERR

POL

Indicates a polarity
error.

PLS

WAIT

Indicates a UIM
communication error.

UNIT

MEM

Indicates a memory
CRC PCM error.

OVER

CRNT

Indicates an
overcurrent error.

MOTR COM

• The motor communication error indi-

cates motor board lost data communica­tions. Press Jog/Purge button to clear error.

PLS WAIT

• The uim communication error indicates

user interface board lost data
communications. Press Jog/Purge button
to clear error.

OVER CRNT

• The over current error indicates welding

power source primary current is too high.
Check and correct input power. Press Jog/
Purge button to clear error.

LOW WFS

• The low wire feed speed error indicates

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

UIM

MEM

Indicates a memory
CRC UIM error.

LOW

WFS

Indicates a low WFS
command error.

OM-228 956 Page 30

7-2. Diagnostics (Continued)

RMD

DONE

Indicates RMD
demo is done.

RMD DONE

• The RMD done message indicates the

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

OVER AVER

• The over average error indicates that

current is outside the average range for the
set program parameters. Check and correct
program parameters. Press Jog/Purge
button to clear error.

OVER

AVER

Indicates an over
average current error.

7-3. Troubleshooting

UNIT

COMM

Indicates a CRC
PCM bus error.

UNIT COMM

• The unit communication error indicates

the data bus on the PCM board is not
functioning properly. Press Jog/Purge
button to clear error.

REL TRIG

• The release trigger error indicates the

user held the gun trigger after a timed weld
was completed causing the contactor to
remain on. Press Jog/Purge button to clear
error.

REL

TRIG

Indicates a contactor
on error.

TRIG

STUK

Indicates a trigger
closed error.

TRIG STUK

• The trigger stuck error indicates the user

held the gun trigger during power up. Press
Jog/Purge button to clear error.

ERR UNKN

• The unknown error indicates a

malfunction in the system somewhere.
Press Jog/Purge button to clear error.

ERR

UNKN

Indicates an
unknown error.

Y Disconnect power before troubleshooting

Trouble Remedy

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

Electrode wire feeding stops or feeds
erratically during welding.

Motor runs slowly. Check for correct input voltage.

Wire feeder power is on, displays light
up, but unit is inoperative.

Check and secure weld cable connections (see Section 4-2).

Check gun trigger connection. See gun Owner’s Manual.

Check gun trigger. See gun Owner’s Manual.

Readjust hub tension and drive roll pressure (see Section 4-9).

Change to correct size drive roll (see Table 9-1).

Clean or replace dirty or worn drive roll.

Incorrect size or worn wire guides.

Replace contact tip or liner. See gun Owner’s Manual.

Remove weld spatter or foreign matter from around nozzle opening.

Have Factory Authorized Service Agency check drive motor or motor control board PC1.

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

OM-228 956 Page 31

SECTION 8 − ELECTRICAL DIAGRAM

OM-228 956 Page 32

Figure 8-1. Circuit Diagram

211 005-D

OM-228 956 Page 33

SECTION 9 − PARTS LIST

6

7

. Hardware is common and

not available unless listed.

4 − Fig 9-3, 9-4

8

9

10

11

15

16

17

3

22

2

18

1

5

12

11

10

13

14

OM-228 956 Page 34

19

20

21 − Fig 9-2

804 588-A

Figure 9-1. Main Assembly

Item

No.

Part

No.

Description

Figure 9-1. Main Assembly

1 159 647 INSULATOR, motor clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 159 646 CLAMP, motor base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 159 360 INSULATOR, screw machine 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Figures 9-3, 9-4 DRIVE ASSEMBLY, wire 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 141 753 HUB & SPINDLE ASSEMBLY, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 058 427 RING, retaining spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 180 571 SHAFT, support spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 010 233 SPRING, cprsn .970 OD x .120 wire x 1.250pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 057 971 WASHER, flat stl keyed 1.500dia x .125thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 010 191 WASHER, fbr .656 ID x 1.500 OD x .125thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 058 628 WASHER, brake stl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 058 428 HUB, spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 135 205 NUT, stl slflkg hex reg .625-11 w/nylon insert 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 200 556 SUPPORT, spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 201 781 KNOB, w/extension clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 228 131 CLAMP, motor top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 145 639 STRIP, buna N compressed sheet .062 x 4.000 x 4.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 200 552 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 134 306 FOOT, rubber 1.250 dia x 1.375 high no 10 screw 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 200 557 STIFFENER, base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 Figure 9-2 CONTROL BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 216 695 CAPACITOR, w/terminals (.027UF) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

*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-228 956 Page 35

. Hardware is common and

not available unless listed.

24

1

23

22

2

6

5

4

3

17

16

19

20

21

7

25

8

15

16

14

9

10

11

12

13

803 507-D

Figure 9-2. Control Box

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 9-2. Control Box (Fig 9-1 Item 21)

1 134 464 LABEL, Warning General Precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +212 781 WRAPPER, feeder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*211 164 PANEL, pc card switch/overlay (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 210 655 NAMEPLATE, overlay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC5 227 879 CIRCUIT CARD ASSY, switches 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC7 204 049 CIRCUIT CARD ASSY, display/micro w/program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 212 808 BAFFLE, pc mounting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC6 *209 681 CIRCUIT CARD ASSY, motor control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 211 003 ENCLOSURE, motor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 010 494 BUSHING, snap−in nyl 1.375 id x 1.750 mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 057 357 BUSHING, snap−in nyl .937 id x 1.125 mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 RC1 211 018 CONNECTOR, circ 97/met 9 pin size 20 rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG43,46,49,. . . . . .

72 115 093 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 605 227 NUT, 750−14 knurled1.68dia .41h nyl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 219 047 VALVE, 40 VDC 2 way custom port 1/8 orf w/frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 134 201 STAND−OFF SUPPORT, pc card 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 097 132 STAND−OFF SUPPORT, pc card 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 211 002 ENCLOSURE, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PC2 212 493 CIRCUIT CARD ASSY, motor filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 S1 213 632 SWITCH, rocker dpdt 10A 250VAC/20A 30VAC on-none-on 1. . . . . . . . . . . . . . . . . . . . . . . . .

19 PC1 212 459 CIRCUIT CARD ASSY, trigger filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 RC4 048 282 RCPT W/SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 211 085 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-228 956 Page 36

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 9-2. Control Box (Fig 9-1 Item 21) (Continued)

22 228 270 NAMEPLATE, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 210 998 SWITCH ASSY, jog/purge (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 S2 200 295 SWITCH, rocker spdt 15A 12V (on)-off-(on) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131 056 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131 052 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 179 851 KNOB, pointer 1.670 dia x .250 id push on w/spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 216 866 FILTER ASSY, sense lead (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216 696 CAPACITOR, w/terminals (.027UF) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 855 BLOCK, term 20 amp 2 pole screw term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224 383 RESISTOR, w/terminals (2 K 5 watt) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216 872 CABLE, volt sense 7 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 004 CABLE, volt sense 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG47 115 094 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG48 202 592 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 136 810 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG81 115 092 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 130 203 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG50 136 810 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG44 131 058 HOUSING PLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG45 188 352 HOUSING RCPT+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG42 131 054 HOUSING RCPT+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG40 201 665 HOUSING RCPTPLUG+SKTS, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207 676 STAND−OFF, no 6-32 x .250 lg .250 hex 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

*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-228 956 Page 37

. Hardware is common and

not available unless listed.

See Table 9-1 For

Drive Roll & Wire Guide Kits

4

3

8

7

2

6

5

9

Item
No.

1

21

20

Diagram

marking

22

17

18

19

16

Figure 9-3. Drive Assembly, Wire

Part
No. Description

9-3. Drive Assembly, Wire (9-1 Item 4)

15

12

10

2

11

13

14

804 186-A

Quantity

1 224 772 Drive Assy, Mechanical Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 219 126 Screw, Shld Stl Sch .375−16 X .500 X 1.000 Shld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 219 098 Insulator, Base/Mtg Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 108 943 Screw, 250−20x1.50 Hexwhd.61D Gr5 Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 219 133 Screw, 375−16x1.50 Hexwhd.81D Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 093 664 Gear, Spur Insulated Drive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 079 625 Washer, Wave .500 Idx0.750 Odx.015t Stl Lbs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 605 308 Ring, Rtng Ext .500 Shaft X .035 Thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 601 941 Screw, 250−20x1.75 Hexwhd.61D Gr5 Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 219 132 Screw, 375−16x2.00 Hexwhd.81D Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 602 241 Washer, Flat .281 Idx0.625 Odx.065t Stl Pld Ansi.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 181 221 Screw, 250−20x .50 Button Hd−Soc Stl Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 092 865 Key, Stl .1215/.1230 X .750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 219 084 Pressure Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 144 172 Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 219 093 Block, Gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 219 092 Clamp, Pin Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 219 136 Lock, Pin Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 219 096 Knob, Tri−Lobe W/.375−16 Stud 2.500 Lg Blk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 219 125 Screw, 010−32x .50 Soc Hd−Hex Pln 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 219 091 Holder, Guide Intermediate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 219 129 Screw, 010−32x1.50 Soc Hd−Hex Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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-228 956 Page 38

. Hardware is common and

not available unless listed.

1

3

2

4

804 589-A

Figure 9-4. Drive Assembly, Wire

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 9-4. Drive Assembly, Wire (Fig 9-1 Item 4)

1 220 012 SCREW, 250-28x.62 button soc-hd zinc 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Figure 9-3 DRIVE ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 M1 *227 024 MOTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 {229550 ENCODER, quadrature 500PPR incremental 5V shaftless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.

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-228 956 Page 39

UC Groove

v

e

o

t

e

S

P
e

e

o

s

D

o

o

D
Ta

r

e

0

D

o

0

3

S

a

083 489

083 490

053 708

ed)

ve Rolls

(4 requir

Standard Dri

uides

tyle Drive

olls and G

tyle) Drive R

PD (Old-

equired)

Rolls (1 each r

Guides for Old S

PD and

Old Style

UC Groove

U Groove

V Groove

Exit

Guide

Guide

Intermediate

Inlet

Guide

132 957

053 701

053 697

223 517

223 515

219 108

132 956

053 702

053 698

223 517

223 515

219 108

132 955

053 706

053 699

223 517

223 515

219 108

m

e) and Non-

ion Driv

(Preci

able 9-1. P

e required)

for Aluminu

olls & 1 guid

P

(1 kit or 4 r

e required)

ire

for Hard Wi

olls & 1 guid

P

(1 kit or 4 r

ize

PD

Continuous

PD

Roll

Drive

PD Kit

PD

Continuous

PD

Roll

Drive

Guide

Guide

PD Kit

Metric

223 100

227 770

300 040

223 097

222 498

224 875

1.1-1.2 mm

223 101

222 499

223 097

222 499

224 876

1.3-1.4 mm

223 101

olls.

227 772

ove” drive r

300 041

D-U U-Gro

223 098

0041 contain “P

222 500

0040 and 30

224 877

300039, 30

1.6 mm

luminum kits

Wire

Fraction

.045-.047 in

.052 in

(0.62)

1/16 in

Note: PD for

OM-228 956 Page 40

Notes

Notes

Warranty Questions?

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

Your distributor also gives
you ...

Service

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

Support

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

Effective January 1, 2006

(Equipment with a serial number preface of “LG” 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 date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent 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 2006−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts)
Circuit Diagrams
Welding Process Handbooks

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

Miller Electric Mfg. Co.

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

International Headquarters−USA

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

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 © 2006 Miller Electric Mfg. Co.2006−01