Miller Electric MILLERMATIC 350P User Manual

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Page 1

OM-1327 213 814AD

2010−04

Processes

MIG (GMAW) Welding Pulsed MIG (GMAW-P)

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source and Wire Feeder

Millermatic 350 And

Millermatic 350P

Visit our website at

www.MillerWelds.com

File: MIG (GMAW)

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From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

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

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

Mil_Thank 2009−09

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TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3-2. Duty Cycle And Overheating 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curve 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Connecting To Weld Output Terminals 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing Work Clamp 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Installing Welding Gun/Cable Holder 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Installing Welding Gun 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Connecting Spoolmatic) 15A Or 30A Gun 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Connecting XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro 16. . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Setting Gun Polarity For Wire Type 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Installing Gas Supply 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Installing Wire Spool and Adjusting Hub Tension 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Electrical Service Guide 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Selecting Input Voltage (200/230/460 Volt Models Only) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15. Serial Number And Rating Label Location 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16. Selecting A Location And Connecting 3-Phase Input Power 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17. Selection A Location And Connecting 1-Phase Input Power 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-18. Threading Welding Wire For MIG Gun 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-19. Threading Welding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro 24. . . . . . . . . . . .

3-20. Threading Welding Wire Through XR Guns 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. MIG Mode 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Jog Mode 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Weld Status 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. MIG Gun-On-Demand 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Pulse MIG Mode Voltage Adjustment 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Pulse MIG Gun-On-Demand 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Tip Saver 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Weld Parameters For MIG Mode 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Weld Parameters For Pulse Mode 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

SECTION 5 − PROGRAMMING 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. MIG Welding Mode 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Pulse MIG Welding Mode 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Timers 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill 33. . . . . . . . . . . . . . . . . . . . . . .

5-5. Setting Hot Start (Aluminum Pulse Only) Parameters 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Setting Crater Fill 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Recommended Crater Fill Parameters 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. System Reset 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Motor Calibration Function 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Set Up Push Motor Torque (SUP) 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE &TROUBLESHOOTING 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Overheating 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Measuring Input Capacitor Voltage 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Changing Drive Roll and Wire Inlet Guide 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Help Displays 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Troubleshooting 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAM 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

Page 5

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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

1-1. Symbol Usage

som _2010−03

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

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

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

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

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

D Do not touch live electrical parts.

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

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

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

there is a danger of falling.

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

unit.

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

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

D Disconnect input power or stop engine before installing or

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

. Indicates special instructions.

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

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

and sparks.

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

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.

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

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

HOT PARTS can burn.

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

ment.

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

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

OM-1327 Page 1

Page 6

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.

ARC RAYS can burn eyes and skin.

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

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

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

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

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

WELDING can cause fire or explosion.

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

burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see Safety Standards).

D Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

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

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

D Do not use welder to thaw frozen pipes.

OM-1327 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF can affect ImplantedMedical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

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

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise 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.

Page 7

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

D Do not install unit near flammables.

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

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

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

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

extend beyond opposite side of unit.

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

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

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

OVERUSE can cause OVERHEATING

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

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

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

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

MOVING PARTS can injure.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

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

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

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

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

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

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

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

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

OM-1327 Page 3

Page 8

1-4. California Proposition 65 Warnings

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

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

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

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

al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).

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

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org).

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

For Gasoline Engines:

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

For Diesel Engines:

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

25 West 43rd Street, New York, NY 10036 (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,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

1-6. EMF Information

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

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

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

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

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

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

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

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

About Implanted Medical Devices:

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

OM-1327 Page 4

Page 9

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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

2-1. Symboles utilisés

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

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

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

. Indique des instructions spécifiques.

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

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

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

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

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

UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.

Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.

D Ne pas toucher aux pièces électriques sous tension. D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.

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

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

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

MENT si le procédé de soudage le demande.

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

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

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

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

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

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

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

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

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

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

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

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chaudes.

D Vérifier fréquemment le cordon d’alimentation afin de s’assurer

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

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

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

avec un câble distinct.

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

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

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

en place.

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

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

fre_som_2010−03

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Page 10

Il reste une TENSION DC NON NÉGLIGEABLE dans

les sources de soudage onduleur UNE FOIS l’alimentation coupée.

D Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.

LES PIÈCES CHAUDES peuvent provoquer des brûlures.

D Ne pas toucher à mains nues les partie

chaudes.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

LES FUMÉES ET LES GAZ peuvent être dangereux.

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

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

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

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

approuvé.

D Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, 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 dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

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

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

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

Le rayonnement de l’arc du procédé de soudag

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure dans les yeux et sur la peau. Des étincelles sont projetées pendant l soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.

D Porter des vêtements confectionnés avec des matières résistan-

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

OM-1327 Page 6

génère des rayons visibles et invisibles intense

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

D Déplacer toutes les substances inflammables à une distance de

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

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

sur des substances inflammables.

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

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

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

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

D Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.

D Le soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.

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

facial.

Page 11

LES ACCUMULATIONS DE GAZ

a e

risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz protecteur en cas

de non-utilisation.

D Veiller toujours à bien aérer les espaces confi-

nés ou se servir d’un respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques

et autres implants médicaux doivent rester à distance.

D Les porteurs d’implants médicaux doivent consulter

leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser

si elles sont endommagées.

Des bouteilles de gaz protecteur contiennent du gaz

sous haute pression. Si une bouteille est endom-

magée, elle peut exploser. Du fait que les bouteilles

soudage, les manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état.

D Détourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

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

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

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

samment de personnes pour soulever et déplacer les bouteilles.

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

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité.

de gaz font normalement partie du procédé de

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

Risque D’INCENDIE OU D’EXPLOSION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

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

LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un équipement de levage de capacité

suffisante pour lever l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assu-

rer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.

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

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

stance inflammable.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage e

les yeux.

D Affûter l’électrode au tungstène uniquement à l

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

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les cir-

cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antista-

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

OM-1327 Page 7

Page 12

Les PIÈCES MOBILES peuvent causer des blessures.

D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

Les PIÈCES MOBILES peuvent causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de

dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’entretien en respectant les manuels d’utilisation, les

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

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de

provoquer des interférences.

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

provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

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

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

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

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

compatible électromagnétiquement.

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

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

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

ment électronique sensible.

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

conformément à ce mode d’emploi.

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

tes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’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)

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.

Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent

OM-1327 Page 8

Pour les moteurs à essence :

Pour les moteurs diesel :

des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après

utilisation.

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

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

Page 13

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).

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, 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, Quincy, MA 02269 (téléphone : 800-344-3555, site Internet : www.nfpa.org et www.sparky.org).

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

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone : 800-463-6727, site internet : www.csa-international.org).

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

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Les CEM peuvent créer des interférences avec certains implants médicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.

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

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

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

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

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

U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet: www.cdc.gov/NIOSH).

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

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

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

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

En ce qui concerne les implants médicaux :

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

OM-1327 Page 9

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3-1. Specifications

. A complete Parts List is available at www.MillerWelds.com

SECTION 3 − INSTALLATION

Max. Open

Circuit

Voltage

60 Hz

Single-Phase

Three-Phase

.035 − .047 in. (0.9 − 1.2 mm)

200 V 230 V 460 V 575V KVA KW

69 (1.7*)

34 (1.7*)

(1.3−17.8 m/min)

Rated Output

300 A at 32 VDC, 60% Duty Cycle

* While idling

Solid Steel Stainless Steel Aluminum 50−700 IPM .023 − .045 in.

(0.8 − 1.1 mm)

Operating Temperature Range: −20C to +40C Storage Temperature Range: -30C to + 50C

350 A at 32 VDC, 40% Duty Cycle

Wire Type and Diameter Wire Feed Speed Dimensions Net Weight

.030 − .045 in. (0.8 − 1.1 mm)

Amps Input at Rated Output

61 (1.5*)

30 (1.5*)

30 (0.75*)

15 (0.75*)

H: 34 in. (864 mm) W: 19 in. (483 mm) D: 41 in. (1041 mm)

24 (0.5*)

12 (0.5*)

3-2. Duty Cycle And Overheating

500 400

300 250

225 200

150

WELDING AMPERES

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

If unit overheats, thermistors open, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

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

13.1 11.2

11.6 11.5

181 lb (82 kg)

100

10 15 20 25 30 40 50 60 70 80 90 100

% DUTY CYCLE

60% Duty Cycle At 300 Amperes 40% Duty Cycle At 350 Amperes

6 Minutes Welding 4 Minutes Resting

Overheating

Minutes

4 Minutes Welding 6 Minutes Resting

A or V

Reduce Duty Cycle

sduty1 5/95 / 217 442-A

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. A complete Parts List is available at www.MillerWelds.com

3-3. Volt-Ampere Curve

VOLTAGE

0 50 100 150 200 250 300 350

AMPERAGE

MAX V OLT S MI N V OL TS

1 Normal Volt-Ampere Curves The volt-ampere curves show the

normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

3-4. Connecting To Weld Output Terminals

Do not place

anything between

weld cable terminal

and copper bar.

Tools Needed:

3/4 in. (19 mm)

! Turn off power before connecting to

weld output terminals.

! Failure to properly connect weld

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

Correct Installation

1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output ter-

minal. Slide weld cable terminal onto weld

217 443-A

803 778-A

Incorrect Installation

output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld

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

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. A complete Parts List is available at www.MillerWelds.com

3-5. Installing Work Clamp

1 Work Cable 2 Boot Route cable through front panel

opening. Slide boot onto work cable.

3 Negative (−) Output Terminal Connect cable to terminal and

cover connection with boot. Close door.

3-6. Installing Welding Gun/Cable Holder

Tools Needed:

3/4 in.

803 540-C

1 Welding Gun/Cable Holder 2 Wrapper 3 Screw Locations Remove screws from side panel.

Place holder against side panel and align screw holes. Secure holder to side panel with the previously removed screws.

Ref. 803 545-D / Ref. 803 539-C

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. A complete Parts List is available at www.MillerWelds.com

3-7. Installing Welding Gun

1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun

end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob.

4 Gun Trigger Plug Insert plug into receptacle, and

tighten threaded collar. Close door.

Ref. 803 541-C

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. A complete Parts List is available at www.MillerWelds.com

3-8. Connecting Spoolmatic) 15A Or 30A Gun

1 Gun Trigger Plug Insert plug into receptacle, and

tighten threaded collar. 2 Weld Cable 3 Shielding Gas Hose Route weld cable and gas hose

through opening in front panel. 4 Positive Weld Output Terminal Connect weld cable to weld output

terminal. 5 Regulator/Flowmeter Route shielding gas hose through

wire drive compartment, out opening in rear panel, and up to regulator/flowmeter. Connect gas hose to regulator/flowmeter.

Tools Needed:

3/4, 5/8 in.

803 568-D

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. A complete Parts List is available at www.MillerWelds.com

3-9. Connecting XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro

. XR Edge guns prior to serial no.

LE079101 require an adapter cord (part no. 195 498).

1 Gun End 2 Gun Liner 3 Wire Outlet Guide Trim excess liner from end of gun

so no more than 3/32 in. (2.4 mm) of liner extends past wire outlet guide.

4 Gun Securing Knob

Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob.

Be sure to change drive rolls to the proper size and type.

5 Gun Trigger Plug Insert plug into receptacle, and

tighten threaded collar.

. Be sure to trim liner to proper extension.

3/32 in.

(2.4 mm)

OM-1327 Page 16

803 569-C / Ref. 803 570 -C / Ref. 803 463

Page 21

. A complete Parts List is available at www.MillerWelds.com

3-10. Setting Gun Polarity For Wire Type

Changing Polarity

1 Polarity Changeover Information Always read and follow manufacture’s

recommended polarity.

Wire Drive

Assembly Lead

Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW).

Electrode Negative (DCEN): Reverse lead connections at terminals from that shown above for gasless flux core wires (FCAW). Drive assembly becomes negative.

Positive

Terminal

Work Clamp Lead

Negative

Terminal

3/4, 11/16 in.

Ref. 803 541-A

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. A complete Parts List is available at www.MillerWelds.com

3-11. Installing Gas Supply

Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve.

Argon Gas Or Mixed Gas

8 9

CO2 Gas

1 Cap 2 Cylinder Valve Remove cap, stand to side of

valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.

3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection

Connect supplied gas hose between regulator/flowmeter gas hose connection, and fitting on rear of welding power source.

7 Flow Adjust Typical flow rate is 20 cfh (cubic

feet per hour). Check wire manufacturer’s recommended flow rate.

8CO2 Adapter (Customer

Supplied) 9 O-Ring (Customer Supplied) Install adapter with O-ring between

regulator/flowmeter and CO cylinder.

Rear Panel

Tools Needed:

1-1/8, 5/8 in.

803 542-C

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. A complete Parts List is available at www.MillerWelds.com

3-12. Installing Wire Spool and Adjusting Hub Tension

Use compression spring with 8 in (200 mm) spools.

When a slight force is needed to turn spool, tension is set.

Tools Needed:

15/16 in.

Ref. 805 023-A

3-13. Electrical Service Guide

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

60 Hz Single Phase 60 Hz Three Phase

Input Voltage (V) 200 230 460 575 200 230 460 575 Input Amperes (A) At Rated Output 69 61 30 24 34 30 15 12 Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Reference: 2008 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

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

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

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

NOTICE − This unit is either a 200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label.

80 70 35 25 40 35 15 10

100 90 40 35 50 45 20 15

6 8 10 12 10 10 14 14

101 (31)86(26)

8 8 10 12 10 10 14 14

229 (70)

217 (66)86(26)

114

(35)

178 (54)

227 (85)

OM-1327 Page 19

Page 24

. A complete Parts List is available at www.MillerWelds.com

3-14. Selecting Input Voltage (200/230/460 Volt Models Only)

. Be sure to reinstall all four screws

securing relinking board in place.

! Turn Off welding power

source, disconnect input power, and check voltage on input capacitors according to Section 6-3 before proceeding.

. Check input voltage available

at site.

. Incorrect linking can damage

unit and void the warranty.

1 Voltage Selection View

Window

Check voltage selected in unit. Changing selection is only necessary if selected value does not match available input voltage.

2 Relinking Board PC6 3 Mounting Screws 4 Receptacle RC23

(Connection For 230 VAC Input Power)

5 Receptacle RC46

(Connection For 460 VAC Input Power)

Move relinking board as needed and connect plug PLG32 (in unit) to RC23 or RC46 according to input power voltage.

Tools Needed:

OM-1327 Page 20

5/16 in.

803 539-C / 804 042-A

Page 25

. A complete Parts List is available at www.MillerWelds.com

3-15. Serial Number And Rating Label Location

The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

3-16. Selecting A Location And Connecting 3-Phase Input Power

18 in. (457 mm)

for airflow

Rear Panel

! Do not move or operate

unit where it could tip.

= GND/PE Earth Ground

L2 L3

Tools Needed:

! Installation must meet all National and

Local Codes - have only qualified persons make this installation.

! Disconnect and lockout/tagout input

power before connecting input conductors from unit.

! Always connect green or green/yellow

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

! Warning: This unit is either a

200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage

available at site to be sure it matches the voltage specified on the rating label.

1 Input Power Cord Strain Relief 2 Input Power Cord 3 Disconnect Device (switch shown in

the OFF position)

4 Green Or Green/Yellow Grounding

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

Ref. 803 543-E / 803 766-A

conductor to disconnect device grounding terminal first.

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

8 Over-Current Protection

Select type and size of over-current protection using Section 3-13 (fused disconnect switch shown).

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

OM-1327 Page 21

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. A complete Parts List is available at www.MillerWelds.com

3-17. Selection A Location And Connecting 1-Phase Input Power

18 in. (457 mm)

for airflow

Rear Panel

! Do not move or operate

unit where it could tip.

=GND/PE Earth Ground

Tools Needed:

! Installation must meet all National and

Local Codes - have only qualified persons make this installation.

! Disconnect and lockout/tagout input

power before connecting input conductors form unit.

! Always connect green or green/yellow

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

! Warning: This unit is either a

200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label.

Three Conductor Power Cord Preparation

1 Input Power Cord Strain Relief 2 Input Power Cord 3 Black And White Input Conductors (L1

And L2) 4 Red Input Conductor 5 Green Or Green/Yellow Grounding

Conductor 6 Insulation Sleeving 7 Electrical Tape Insulate and isolate red conductor as shown.

Disconnect Device Input Power Connections

8 Disconnect Device (switch shown in

the OFF position)

Ref. 803 543-E / 803 766-A

9 Disconnect Device Grounding Terminal 10 Disconnect Device Line Terminals

Connect green or green/yellow grounding conductor (see Item 5) to disconnect device grounding terminal first.

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

11 Over-Current Protection

Select type and size of over-current protection using Section 3-13 (fused disconnect switch shown).

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

OM-1327 Page 22

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. A complete Parts List is available at www.MillerWelds.com

3-18. Threading Welding Wire For MIG Gun

1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide

6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight.

21 4

Tools Needed:

. Hold wire tightly to keep

it from unraveling.

6 in.

(150 mm)

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;

Tighten

. Use pressure indicator scale to set

a desired drive roll pressure.

1 2 3 4

Pressure

Indicator

Scale

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle

Remove gun nozzle and contact tip. Turn On.

Tighten

1 2 3

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

803 570-C / S-0627-A

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. A complete Parts List is available at www.MillerWelds.com

3-19. Threading Welding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro

1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide

6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight.

Open pressure assembly.

35621 4

IMPORTANT! For Aluminum Push-Pull welding. Thread hub tension nut loosely

218243-A

Tighten

Tools Needed:

. Hold wire tightly to keep

it from unraveling.

6 in.

(150 mm)

Pull and hold wire; cut off end.

IMPORTANT! For Aluminum Push-Pull welding.

Push wire thru guides into gun;

continue to hold wire.

See Section 3-20 for threading welding wire through XR guns.

OM-1327 Page 24

Close and tighten pressure

assembly, and let go of wire.

1 2 3 4

Pressure

Indicator

Scale

218244-A

. Use pressure indicator scale to

set front drive roll pressure to 1 and rear drive roll pressure to less than 1.

Ref. 803 544-B / 218 243-A / 218 244-A / S-0627-A

Page 29

. A complete Parts List is available at www.MillerWelds.com

3-20. Threading Welding Wire Through XR Guns

For XR-A Edge Gun:

Turn On

Welding Power

Source.

Remove barrel assembly before threading wire through gun.

! Welding wire is electrically live

when gun trigger is used to jog wire.

. Refer to Section 3-19 for instructions

on feeding wire through welding power source.

1 Pressure Roll Assembly Lay gun cable out straight. Open top cover, and open pressure roll as-

sembly. If not already done, remove gun barrel assembly.

Press gun trigger until about 4 in. (102 mm) of wire is sticking out front of gun. Insert wire into barrel liner and tighten barrel assembly. Install correct size contact tube and install collet nut.

Close top cover on gun. Press trigger switch until about 6 in. (152 mm) of wire is sticking out end of contact tip. Cut off wire. Close and latch door.

. XR Edge gun drive roll pressure

should be set at minimum.

For XR-A Pistol Gun:

Turn On

Welding Power

Source.

For XR-A Pistol Gun:

Remove barrel assembly

before threading wire

through gun.

1 Pressure Roll Assembly 2 Drive Roll 3 Thumbscrew Lay gun cable out straight. Open top

cover, and lift pressure arm and open pressure roll assembly. If not already done, remove gun barrel assembly.

Manually thread wire along drive roll groove. Close pressure roll assembly. Press gun trigger until about 4 in. (102 mm) of wire is sticking out front of gun. Insert wire into barrel liner and tighten barrel assembly. Install correct size contact tube and install collet nut. Reinstall gun cover.

4 Pressure Adjustment Knob See final pressure adjustment at bottom of

page.

Tools Needed:

Nonconductive

Surface

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

. Do not exceed midrange setting.

Cut off wire. Close and latch door.

! Turn welding power source Off.

Ref. 802 193-A / 801 556 / Ref. 151 666-C

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4-1. Controls

. A complete Parts List is available at www.MillerWelds.com

SECTION 4 − OPERATION

1 2

3 4 5

1 Pulse Indicator Light

. Pulse only lights if unit has the pulse

MIG module and is programmed for pulse MIG.

2 MIG Indicator Lights Pulse (1) and MIG (2) illuminate to Indicate

weld mode of unit. 3 Process Light PROCESS illuminates when unit is in

Process select menu. 4 Wire Light WIRE illuminates when unit is in Pulse MIG

program select menu. 5 Timers Light TIMERS illuminates when unit is in Timers

menu. 6 Setup Button

Use button to access Timers, Process and Wire menus.

7 Arc Control Button

Use button to select either inductance control in MIG welding mode or Sharp Arc in Pulse MIG welding mode.

8 Left Knob

Use knob to adjust volts in MIG welding mode or change parameter values in Setup.

9 Right Knob

Use knob to adjust wire speed in MIG welding mode or change parameter values in Setup.

10 Left Display 11 Right Display

12 Weld Functions/Setup Indicator

Lights

VOLTS illuminates in MIG welding mode indicating volts in left display can be adjusted. Also, VOLTS lights to indicate left display is showing actual voltage during welding and for 5 seconds after the arc is extinguished.

ARC LENGTH illuminates in Pulse MIG welding mode indicating Arc Length can be adjusted.

SETUP illuminates when a parameter on the corresponding display above the light can be adjusted.

WIRE SPEED illuminates in either Pulse MIG or MIG welding mode indicating wire speed can be adjusted.

AMPS illuminates indicating welding amps appears in the display, instead of wire speed, during welding and for 5 seconds after the arc is extinguished.

Ref. 213 935-A

. The first time the welding power source is energized it starts in MIG welding mode. Each time after the initial startup, when the unit is turned off,

whatever mode and parameter settings were last set will remain as the current settings the next time the unit is energized.

4-2. MIG Mode

In MIG mode, VOLTS is lit under left display and WIRE SPEED is lit under right display. Left knob is used to adjust welding voltage within a range of 10-32 volts, and right knob is used to adjust wire feed speed within a range of 25-700 IPM. Refer to weld chart in front compartment for proper parameter settings according to wire type, shielding gas, and material type and thickness.

4-3. Jog Mode

If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld power. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow

OM-1327 Page 26

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. A complete Parts List is available at www.MillerWelds.com

because gas valve is located inside spool gun. For MIG guns, wire will feed for up to 2 minutes while trigger is pressed, then wire drive system in unit will automatically shut off. For spool guns, wire will feed for up to 30 seconds before shutting off. If gun trigger is pressed for 3 seconds without striking an arc the displays will show JOG MODE.

4-4. Weld Status

When trigger is released on a MIG gun, spool gun, or push-pull gun, the last actual amperage and voltage will be shown on the displays for 5 seconds. The VOLTS and AMPS indicator lights will illuminate under the displays and each value will appear in the corresponding display.

If a programmed value requires adjustment after the arc is extinguished and during the 5 seconds display of actual values, turning either knob will cause actual values in the displays to be replaced by programmed values for adjustment purposes.

. The 5 second delay after the arc is extinguished for displaying actual weld values can be turned on or off in the Timer menu DISP selection (see

Section 5-3).

4-5. MIG Gun-On-Demand

The guns that can be used with this unit are MIG guns, spool guns, and push-pull guns. To switch from one gun to another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun. If the unit is powered down and back on again, the gun last used will become the current active gun.

4-6. Pulse MIG Mode Voltage Adjustment

In Pulse MIG mode there is no manual voltage adjustment; instead, voltage is synergically aligned with the proper wire feed speed. Arc Length adjustment is used to adjust actual arc length which automatically adjusts the voltage. See weld chart in front compartment for proper wire feed speed adjustment according to wire size and type.

4-7. Pulse MIG Gun-On-Demand

The spool gun functions slightly different in Pulse MIG mode. To switch from one gun to another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun. For a spool gun, the wire speed is taken from the position of the gun potentiometer. This wire speed value is automatically adjusted if the potentiometer is moved since the last time the gun was active. If the unit is powered down and back on again, the gun last used will become the current active gun.

4-8. Tip Saver

If gun contact tip is directly shorted to the workpiece while gun trigger is pressed, the welding arc automatically shuts off after 1 second to prevent wire burnback in the contact tip.

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. A complete Parts List is available at www.MillerWelds.com

4-9. Weld Parameters For MIG Mode

−

−−−−−

23.5 /220

Volts/Wirefeed

Reference

19.5/175 19.0/160

20.0/235

19.0/450

19.2/380

21.5/450

23.0/530

23.5/700 18.2/300

−

24.0/475 23.5/435 23.0/375 21.5/305 19.5/250

.035 4043

3/64 4043

21.0/520

23.0/66023.5/800

−

3/64 5356 24.0/535 23.5/500 22.5/465 21.0/375 19.0 /340

.035 5356

(4.8mm) (3.2mm) (2.0mm) (1.6mm) (1.2mm) (0.9mm) (0.8mm)

24.0/400 23.0/300 20.5/250

(6.4mm)

23.0/325 21.5/280 20.5/240 20.0/210 19.0 /175 18.5/160 18.0/115 17.0/90 16.5/80

28.5/485 19.5/330 18.5/275 18.0/260 16.5/200 16.0/155 15.5/135 15.0/100 14.5/95

23.0/220 21.5/200 20.5/175 20.0/150 19.0/110 18.5/105 −−−

−

1/2” 3/8” 1/4” 3/16” 1/8” 14ga 16ga 18ga 20ga 22ga

(12.7mm) (9.5mm)

to be modified for other types of welding joints or welding positions.

Wire

.035

MIG CHART MIG CHART

Note: All chart parameters reference settings for Horizontal T fillet welds. Settings may need

Gas

100% Co275% Argon

USE SPRAY 19.0/220 18.0/200 17.5 /170 16.2/150 16.0/130 15.5/100 −

29.3/530

.035

.045

25% Co290% Helium

26.0/400 24.5/350 23.5/300

27.0/42529.0/475

− 25.0 /450 22.5/440 21.5 /375 21.0/325 20.0/275 18.0/235 18.5/200 17.5/150 −

−− −−

.045

.035

.045

7.5% Argon

2.5% Co2100% Argon

90% Argon

10% Co

OM-1327 Page 28

Material

Steel

Inductance = 20−40

Steel

Inductance = 20−40

Stainless Steel

Inductance = 60−80

Metal Core

Inductance = 30

Aluminum

Inductance = 30

Page 33

. A complete Parts List is available at www.MillerWelds.com

4-10. Weld Parameters For Pulse Mode

22ga

19ga

WELDCHARTS

18ga

16ga

14ga

—

(0.8mm)

—

(1.0mm)

(1.2mm)

150

(1.6mm)

200

(2.0mm)

—

100

125

—

100

150

175

—

100

—

130

150

115——

185

125

210

150

———

110

140

150

200

245

310

—

115

165

PULSECHART

190

1/8”

(3.2mm)

3/16”

(4.8mm)

1/4”

(6.4mm)

3/8”

(9.5mm)

1/2”

(12.7mm)

250

300

400

550

650

.035Steel

150

200

300

450

500

.045

125

200

150

300

200

400

325 250

350

500

450

600

475 400

.045

.035StainlessSteel

.045

310

200

450

260

640

550

720

325

—

390

650

—

450

750

3/644043

.0355356

.0354043

290

350

405

550

—

3/645356

PULSECHARPULSECHART

All chart parameters are based

on the following defaults:

arc length − 50, Sharparc[ − 25.

Gas WireMaterial

90%Argon

10%Co

Ar/He/CO2

Tri-Mix

90%Argon

MetalCore

100%Argon

10%Co

Aluminum

OM-1327 Page 29

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. A complete Parts List is available at www.MillerWelds.com

SECTION 5 − PROGRAMMING

5-1. MIG Welding Mode

1 2

3 4

When the MIG light (2) is illuminated, the unit is in MIG Welding mode.

SETUP

To enter MIG welding mode, depress the SETUP (6) button once to go to GUN

selection. Rotate the right knob (9) to select the gun being used. Select MIG for standard MIG gun, or select XR‐A, EDGE, PYTH alpr for push pull guns, or SPL for spoolgun.

Depress SETUP (6) a second time to illuminate the PROCESS (3) light. Rotate right knob (9) until MIG is displayed (for MIG only units NOT USED will be displayed).

Depress SETUP (6) button again to illuminate the WIRE (4) light. Adjust left knob (8) to select wire type, adjust right knob (9) to select wire size.

Depress SETUP (6) button again to illuminate TIMERS (5) light. For description of the TIMERS, refer to TIMERS menu (see Section 5-3)

If crater fill function menus are enabled, TIMERS light will stay on to allow for adjustment of crater parameters and timers (see Section 5-6).

Depress SETUP (6) button again to exit menus and enter MIG welding mode.

OPERATION

Adjust welding Voltage with left knob (8) and Wire Feed Speed with right knob (9). Refer to MIG welding chart for proper Voltage and Wire Feed Speed setting in reference to material type, material thickness, wire, and gas (see Section 4-9).

Ref. 213 935-A

ARC CONTROL

MIG welding mode: Depress ARC CONTROL (7) button to enter Arc control

menu and INDU will appear on the left display and the corresponding setting will appear on the right display. Adjust right knob (9) to adjust inductance setting. In MIG welding mode the Arc control is an inductance control from 0-99. Refer to MIG welding chart for suggested Inductance setting for the wire and gas types being used (see Section 4-9). Changing the inductance will change the fluidity of the puddle.

Low Inductance High Inductance Weld Bead Weld Bead (0 setting) 99 setting

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. A complete Parts List is available at www.MillerWelds.com

5-2. Pulse MIG Welding Mode

1 2

3 4

When the PULSE MIG (1, 2) is illuminated, the unit is in Pulse MIG Welding mode.

SETUP

To enter Pulse MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select the gun being used. Select MIG for standard MIG gun, or select XR‐A, EDGE, PYTH alpr for push pull guns, or SPL for spoolgun.

Depress SETUP (6) a second time to illuminate the PROCESS (3) light. Rotate right knob (9) until PULS is displayed.

Depress SETUP (6) button again to illuminate the WIRE (4) light. Adjust left knob (8) to select wire type, adjust right knob (9) to select wire size.

Depress SETUP (6) button again to exit WIRE menu and enter TIMERS (5) menu. The TIMERS (5) light will illuminate. For description of the TIMERS, refer to TIMERS menu (see Section 5-3)

If crater fill function menus are enabled, TIMERS light will stay on to allow for adjustment of crater parameters and timers (see Section 5-6).

Depress SETUP (6) button again to exit menus and enter PULSE welding mode.

OPERATION

Adjust right knob (9) for proper Wire Feed speed and adjust left knob (8) to change Arc Length if required. Arc length will default to 50 if never adjusted previously. Refer to Pulse MIG welding chart for proper Wire Speed setting for metal and metal thickness being welded (see Section 4-9). All Pulse MIG programs are setup with the gases listed in the Pulse MIG welding chart. If alternate gases are used, adjust Arc Length and/or Sharp Arc (Arc Control) (7) to adjust arc characteristics.

ARC LENGTH

Arc length can be adjusted from 0-99. All Pulse MIG programs are set with a value of

50. Adjusting the Arc Length will vary the length of the welding arc cone.

(0 Setting) (99 Setting)

Low Setting High Setting If a gas is used other than what is listed on

the Pulse MIG welding program chart, the Arc Length can be adjusted to help customize your arc to the gas being used.

Ref. 213 935-A

ARC CONTROL

Pulse MIG (1, 2) welding mode: Depress ARC CONTROL (7) button to enter Arc Control menu for sharp arc. SHRP will appear on the left display and the corresponding setting will appear on the right display. The setting can be adjusted from 0-50 and all Pulse MIG welding programs are designed with a setting of 25. Adjusting the Sharp Arc setting will vary the width of the welding arc cone.

(0 Setting) (50 Setting)

Low Setting High Setting If a gas is used other than what is listed on

the Pulse MIG welding program chart, the Sharp Arc can be adjusted to help customize your arc to the gas being used.

OM-1327 Page 31

Page 36

5-3. Timers

1 2

3 4

. A complete Parts List is available at www.MillerWelds.com

To enter the TIMERS (5) menu depress the

SETUP (6) button 4 times or until the TIMERS light (5) is illuminated.

Items that can be adjusted in this menu are: Run-in speed (R‐IN) − The speed of the

wire prior to the welding arc being struck. This setting is a percentage of the Wire Feed Speed the unit is set to for welding. Programming value ranges from 25-150.

Preflow (PRE) − The amount of time that the shielding gas will flow after the trigger is

depressed and before the welding arc will be allowed to be active. Range of setting is from 0-5 seconds.

Postflow (POST) − The amount of time that the shielding gas will flow after the arc has been shut off. Range of setting is 0-10 seconds.

Spot Timer (SPOT) − The amount of time that the arc will be active before it shuts off automatically. Range of setting is from 0-120 seconds. Spot timer is reset upon release of welding gun trigger.

Ref. 213 935-A

Display (DISP) − Allows the Wire Speed display to show actual welding amperage while arc is active and for 5 seconds after arc is shut off. Setting is either AMPS or WFS for standard Wire Feed Speed.

Once in the TIMERS (5) menu, rotate the left knob (8) to find a particular item, and rotate the right knob (9) to change setting or status.

Depress SETUP (6) button to get out of TIMERS (5) menu and to enter welding mode.

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. A complete Parts List is available at www.MillerWelds.com

5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill

. Accessing the Arc Times, Arc Starts, Hot Start (aluminum pulse only), and Crater Fill data will also allow

access to Software Version data and Motor Calibration function. The software version data and motor calibration function are for use by factory authorized service personnel only. Do not use the motor calibration function if it appears on the displays.

Arc times and number of arc starts are saved in unit memory. To view this information, press both SETUP (1) and ARC CONTROL (2) buttons at the same time.

Left display will initially show arc hours. Rotate left knob (3) and display will change

to show number of arc starts.

To turn on the Crater Fill display, rotate left knob (3) until CRTR appears in the left

display. The factory default for Crater Fill display is OFF which appears in the right display. Rotate the right knob (4) until ON

appears in the display.

. The Crater Fill display can be turned

off after parameters are set in programs, but remember that once crater fill is turned on in any program, it will remain on even though it does not appear in the displays because Crater Fill display is turned off.

To exit this menu, press either the SETUP (1) or ARC CONTROL (2) button, or press a gun trigger on any welding gun connected to the unit.

Ref. 213 935-A

OM-1327 Page 33

Page 38

. A complete Parts List is available at www.MillerWelds.com

5-5. Setting Hot Start (Aluminum Pulse Only) Parameters

. The factory default setting for Hot Start is “Auto” on 350P models. The Auto setting has

preset parameters. Hot Start can also be set to “On” (manual) for customized settings or made inactive when set to Off.

To access the Setup Feature Menu, press both SETUP (1) and ARC CONTROL (2) buttons at the same time.

Left display will initially show arc hours.

Rotate left knob (3) until ALST appears in the left display.

Rotate right knob (4) to select hot start mode as follows:

Auto − default setting for preset hot start parameters

Off − hot start is inactive

On − allows customized setting of hot start parameters

Manual Hot Start Mode

When ALST appears in the left display and

On appears in the right display, the welding

power source is set for manual hot start mode.

To access hot start parameters, press the SETUP (1) button until SPWR appears in the left display.

SPWR − Start Power Range for start power is 100-250 as a per-

cent of wire feed speed.

. SPWR maximum setting will depend

on set wire feed speed and may not allow a setting of 250 under certain conditions.

STMR − Start Time

Ref. 213 935-A

Time range is 0.0-0.5 seconds for hot start to be on.

STRL − Start Arc Length Range for start arc length is 0-99 that

changes arc length from shorter to longer. RMPT − Ramp Time Time range is 0.1-5.0 for the time it takes to

go from hot start to set wire feed speed.

. The two parameters that will have the

largest influence on hot start are Start Power and Start Time. These two parameters will determine how much heat is provided and for how long at the beginning of the weld.

To exit this menu, press the SETUP (1) button.

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Page 39

5-6. Setting Crater Fill

. Crater parameters are welding gun independent (i.e. crater fill can be on for a spool gun and off

for a MIG gun). When using the same welding gun, MIG and pulse programs are independent of each other; however, crater parameters will be the same for all pulse programs. For example, if a MIG gun is using the .035 steel pulse program, and crater fill is on and parameters are set, crater will also be on and the same parameters will be set for a stainless pulse program.

. A complete Parts List is available at www.MillerWelds.com

To set Crater Fill, select a program and press SETUP (1) until the TIMERS LED turns on. Press SETUP again and the left

display will show CRTR and the right display will show OFF.

Rotate right knob (3) to turn crater ON. Rotate left knob (2) to change display to

WFS, and rotate right knob (3) to set crater

wire feed speed. Wire feed speed range is 50-700 IPM (see Section 5-7).

Rotate left knob (2) to change display to TIME, and rotate right knob (3) to set crater time. Time range is 0.1-5.0 seconds (see Section 5-7).

Rotate left knob (2) to change display to

VOLT (MIG program) or ARCL (pulse

program), and rotate right knob (3) to set either volts (range is 10.0-32.0 volts) or arc length [range is 0-99 (see Section 5-7)].

Rotate left knob (2) to change display to TDLY for time delay. This setting is for spot or skip welding without crater fill if the arc time is less than the set time. Time range is

0.0-5.0 seconds (i.e. if TDLY is set for 2.0 seconds, weld operation will not go into crater if gun trigger is released before 2.0 seconds).

To exit this menu, press the SETUP (1) button.

Ref. 213 935-A

OM-1327 Page 35

Page 40

. A complete Parts List is available at www.MillerWelds.com

5-7. Recommended Crater Fill Parameters

Recommended Crater Parameters

What P r oce s s are You Using?

What Material

are You Welding?

Suggested

Wire Types

Suggested

Shielding Gases

Wire Sizes

(Diameter)

1/2”

(12.7mm)

P U L S E

OM-1327 Page 36

Page 41

. A complete Parts List is available at www.MillerWelds.com

3/8” 1/4” 3/16” 1/8”

19ga. 20ga.

(1.05mm)

(0.9mm)

SC-187 212-A

OM-1327 Page 37

Page 42

5-8. System Reset

. Accessing the System Reset function will also allow access to Timer Reset (RTMR)

and Option Reset (ORST) functions. The timer reset and option reset functions are for use by factory authorized service personnel only. Do not use the timer reset or option reset functions if they appear on the displays.

. A complete Parts List is available at www.MillerWelds.com

A system reset function is available that completely resets unit back to all the original factory settings.

To access this menu, turn on welding power source, then press the SETUP (1) button when the SETUP light illuminates under the Left display.

SRST will appear on the left display and OFF

will appear on the right display. To prepare the unit for system reset, rotate

right knob until ON appears on the right display.

Ref. 213 935-A

To apply the system reset function, press SETUP (1) button, and wait until unit completely reboots before performing any other operations.

OM-1327 Page 38

Page 43

. A complete Parts List is available at www.MillerWelds.com

5-9. Motor Calibration Function

Ref. 213 935-A

Perform this function after replacing wire drive motor and/or control circuit board. The motor calibration function automatically calibrates the wire drive motor to enhance arc starting performance and consistency.

. To obtain the most accurate

calibration, set up welding power source in MIG welding mode.

Turn on unit input power. 1 Setup Button 2 Left Knob

3 Left Display 4 Right Knob 5 Right Display 6 Arc Control Button Open drive rolls in welding power source

and in push/pull gun if one is attached to unit.

Simultaneously press Setup and Arc Control buttons.

Rotate left knob until MCAL is displayed. Rotate right knob until YES is displayed.

Press and hold gun trigger. Wire drive speed will be overridden to 50 IPM for 12 seconds and then to 800 IPM for 12 seconds.

When CAL DONE appears on the display, release gun trigger.

Data save will appear on the display while

the calibration data is being stored in the Control board memory.

Close drive rolls in welding power source and push/pull gun.

This completes the motor calibration function, and normal operation can resume.

OM-1327 Page 39

Page 44

. A complete Parts List is available at www.MillerWelds.com

. Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high.

5-10. Set Up Push Motor Torque (SUP)

Ref. 213 935-A

1 Setup Button 2 Left Knob 3 Left Display 4 Right Knob 5 Right Display 6 Arc Control Button Simultaneously press Setup and Arc Control

buttons.

OM-1327 Page 40

Rotate the left knob counterclockwise (CCW) to find the particular item, and rotate the right knob to change the setting.

The following items can be adjusted by rotating the left knob counterclockwise (CCW):

Set up Push Motor Torque (SUP) − This feature is only active when a push/pull gun is connected to the welding power source. The (SUP) setting will adjust the

over-torque limit of the push motor inside the welding power source. The range is 0-250 and the default value is 130. Increasing this setting will increase the over-torque limit and speed up the remote wire feed speed motor.

. If Aluma-Pro push/pull gun has a

listed SUP value, set the power source to match the SUP value.

Page 45

. A complete Parts List is available at www.MillerWelds.com

SECTION 6 − MAINTENANCE &TROUBLESHOOTING

6-1. Routine Maintenance

! Disconnect power

. Maintain more

often during severe conditions.

before maintaining.

Every 3 Months

Every 6 Months

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

l Damaged Or Unreadable Labels

~ Inside Unit ~ Clean Drive Rolls

l Repair Or Replace Cracked Weld Cable

~ Clean And Tighten Weld Terminals

n Check Gun Cable

Reference

6-2. Overheating

Thermistors RT1 and RT2 protect the unit from damage due to overheating. If output diode heatsink or IGBT heatsink gets too hot, RT1 and/or RT2 opens and output stops. The fan keeps running to cool the unit. Wait several minutes before trying to weld.

OM-1327 Page 41

Page 46

. A complete Parts List is available at www.MillerWelds.com

6-3. Measuring Input Capacitor Voltage

! Significant DC voltage can

remain on capacitors after unit is Off. Always check capacitors as shown to be sure they have discharged before working on unit.

Turn Off welding power source and disconnect input power.

Remove case. 1 Input Capacitor C3 Terminals 2 Input Capacitor C4 Terminals 3 Voltmeter Check input capacitors as shown. Measure the dc voltage across the

positive (+) and negative (−) terminals until voltage drops to near 0 (zero) volts.

Proceed with job inside unit. Reinstall case when finished.

Tools Needed:

OM-1327 Page 42

5/16 in.

221 044-A / Ref. 803 550-B

Page 47

. A complete Parts List is available at www.MillerWelds.com

6-4. Changing Drive Roll and Wire Inlet Guide

.045 Groove

Stamped

.035

.035 Groove

Stamped

.045

1 Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to

drive rolls as possible without touching. Tighten screw.

3 Intermediate Guide 4 Drive Roll

. The drive assembly comes

equipped with factory installed .035/.045 combination drive rolls. Be sure that all 4 drive rolls are installed correctly.

Combination drive rolls consist of two different sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the carrier gear is the groove for the wire size viewed on the end surface of the drive roll.

Install correct drive roll for wire size and type.

Tools Needed:

5/64 in.

7/16 in.

. U-Grooved drive rolls are re-

quired for feeding aluminum wire.

5 Drive Roll Securing Nut Turn nut one click to secure drive

roll.

802 520-B

OM-1327 Page 43

Page 48

6-5. Help Displays

. A complete Parts List is available at www.MillerWelds.com

HELP 0

HELP 1

HELP 2

HELP 3

HELP 8

HELP 9

HELP 10

HELP 11

HELP 4

HELP 5

HELP 6

HELP 7

TIP SAVE

MM 350P

MM 350

JOG

XXX

OM-1327 Page 44

Displays a jog wire feed speed.

Page 49

. A complete Parts List is available at www.MillerWelds.com

. All directions are in reference to the

front of the unit. All circuitry referred to is located inside the unit.

S Help 0

Indicates overheating on left side of unit (displays flash between OVER TEMP and HELP 0). Unit will shutdown until internal temperature drops within operational range.

S Help 1

Turn off primary input power and check input voltage per primary voltage rating of welder, and correct if necessary. If HELP 1 persists, this Indicates a communication error between control board PC1 and user interface board. Contact nearest Factory Authorized Service Agent.

S Help 2

Indicates overheating on right side of unit (displays flash between OVER TEMP and HELP 2). Unit will shutdown until internal temperature drops within operational range.

S Help 3

Indicates gun trigger was pulled and held during power up. Release gun trigger and clear fault condition. Also, this display can Indicate no open circuit voltage detected when gun trigger is pulled and no arc detected within 3 seconds. Turn off primary input power and contact a Factory Authorized Service Agent.

S Help 4

Indicates gun trigger was pulled and held for 2 minutes without a welding arc established or there is a direct short between contact tip or wire and the workpiece. Release gun trigger and clear fault condition.

S Help 5

Indicates a malfunction in wire feed system and/or drive motor overcurrent condition. Check for proper spool brake adjustment or obstructions in wire feed system. Clean or replace liner, wire guides, or contact tip.

S Help 6

Indicates a malfunction in wire feed system and/or external drive motor overcurrent condition (spool gun or push-pull gun). Check for proper spool brake adjustment or obstructions in wire feed system. Clean or replace liner, wire guides, or contact tip.

S Help 7

Indicates input voltage malfunction (voltage too high or too low) causing unit to automatically shut down. Turn off input primary power and check input voltage per primary voltage rating of welder. Unit will operate once input voltage is within specification and power to unit is turned off and back on.

S Help 8

Indicates a malfunction in the secondary power circuit of the unit. Check control board PC1, and primary and secondary connections.

S Help 9

Indicates a malfunction in Pulse MIG function. Check connection between pulse board and user interface board. Replace pulse board, if necessary.

S Help 10

Indicates a trigger error when two gun triggers are activated at the same time. Release gun triggers to clear error.

S Help 11

Indicates a tach error when tach feedback signal is not present. Release and press gun trigger to reset tach signal. If error continues, contact a Factory Authorized Service Agent.

S Tip Save

Indicates contact tip is directly shorted to workpiece. Arc shuts off in this condition, and message resets when tip is not touching workpiece and gun trigger is released.

S MM 350P

When unit is turned on, this display indicates that pulse option is installed and operational.

S MM 350

When unit is turned on, this display indicates that unit is either a MIG only machine or pulse option is installed but not operational.

S Jog XXX (Wire Feed Speed)

Indicates trigger is pressed, but no arc is detected. Wire feed speed goes to Jog wire feed speed after 3 seconds.

SC-187 212-A

OM-1327 Page 45

Page 50

. A complete Parts List is available at www.MillerWelds.com

6-6. Troubleshooting

Trouble Remedy

No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-16 or 3-17).

Replace building line fuse or reset circuit breaker if open (see Section 3-16 or 3-17).

Secure gun trigger connections (see Section 3-7).

Have Factory Authorized Service Agent check Power switch.

Have Factory Authorized Service Agent check all board connections and main control board.

No weld output; wire feeds. Thermistor RT1 or RT2 open (overheating). Allow fan to run; the unit will be enabled when it has cooled

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 3-16 or 3-17).

Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1).

No wire feed. Turn Wire Speed control to higher setting (see Section 4-1).

and temperatures are within acceptable limits (see Section 3-2 and 6-2).

Connect work clamp to get good metal to metal contact.

Replace contact tip (see gun Owner’s Manual).

Have Factory Authorized Service Agent check main control board and main rectifier.

Have Factory Authorized Service Agent check main control board and user interface board.

Change to correct size drive rolls (see Section 6-4).

Readjust drive roll pressure (see Section 3-18).

Replace inlet guide, contact tip, and/or liner if necessary (see gun Owner’s Manual).

Have Factory Authorized Service Agent check input voltage.

Have Factory Authorized Service Agent check main control board.

Clear obstruction in gun contact tip or liner (see gun Owner’s Manual).

Readjust drive roll pressure (see Section 3-18).

Change to correct size drive rolls (see Section 6-4).

OM-1327 Page 46

Rethread welding wire (see Section 3-18).

Check gun trigger and leads. Repair or replace gun if necessary.

Have Factory Authorized Service Agent check main control board and user interface board.

H − − message appears on voltmeter and ammeter displays to indicate thermistor RT1 or RT2 is open and unit is in an overheated condition (see Section 6-5).

Page 51

Notes

OM-1327 Page 47

Page 52

SECTION 7 − ELECTRICAL DIAGRAM

OM-1327 Page 48

Figure 7-1. Circuit Diagram For Welding Power Source

Page 53

246 030-B

OM-1327 Page 49

Page 54

SECTION 8 − PARTS LIST

8-1. Drive Roll And Wire Guide Kits

. Base selection of drive rolls upon the following recommended usages:

1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V-Knurled rolls for hard shelled cored wires. 5 Drive roll types may be mixed to suit particular requirements (e.g. V-Knurled roll in combination with U-Grooved).

Wire Diameter

Fraction Decimal Metric

.023/.025 in

.030 in

.035 in

.045 in .052 in 1/16 in

.035 in

.045 in

.052 in

1/16 in

.035 in

.045 in

.052 in

1/16 in

.023/.025 in

.030 in

.035 in

.045 in .052 in .062 in

.035 in

.045 in

.052 in

.062 in .035 in

.045 in

.052 in

.062 in

0.6 mm

0.8 mm

0.9 mm

1.2 mm

1.3 mm

1.6 mm

0.9 mm

1.2 mm

1.3 mm

1.6 mm

0.9 mm

1.2 mm

1.3 mm

1.6 mm

Kit No.

087 132

046 780

046 781

046 782 046 783 046 784

044 750

046 785

046 786

046 787

046 792

046 793

046 794

046 795

. A complete Parts List is available at www.MillerWelds.com

Drive Roll

Part No. Type

087 130

053 695

053 700

053 697 053 698 053 699

072 000

053 701

053 702

053 706 132 958

132 957

132 956

132 955

V-Grooved

V-Grooved V-Grooved V-Grooved

U-Grooved

V-Knurled

Wire Guide

Inlet Intermediate

056 192

056 193 056 193 056 195

056 192

056 193

056 195

056 192

056 193

056 195

056 206

056 207 056 207 056 209

056 206

056 207

056 209

056 206

056 207

056 209

Ref. S-0025-D

OM-1327 Page 50

Page 55

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, 2010

(Equipment with a serial number preface of MA or newer)

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

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

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

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

1. 5 Years Parts — 3 Years Labor * Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules

2. 3 Years — Parts and Labor * Engine Driven Welding Generators

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

* Inverter Power Sources (Unless Otherwise Stated) * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Smith 30 Series Flowgauge and Flowmeter

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

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

4. 1 Year — Parts and Labor Unless Specified * Automatic Motion Devices * CoolBelt and CoolBand Blower Unit (No Labor) * External Monitoring Equipment and Sensors * Field Options

(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.) * Flowgauge and Flowmeter Regulators (No Labor) * RFCS Foot Controls (Except RFCS-RJ45) * Fume Extractors * HF Units * ICE Plasma Cutting Torches (No Labor) * Induction Heating Power Sources, Coolers, and

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

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

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

guarantees or warranties expressed or implied.

6. 90 Days — Parts * Accessory (Kits) * Canvas Covers * Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls * M-Guns * MIG Guns and Subarc (SAW) Guns * Remote Controls and RFCS-RJ45 * Replacement Parts (No labor) * Roughneck Guns * Spoolmate Spoolguns

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)

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

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

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

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at 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 2010−01

Page 56

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: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

For International Locations Visit

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.

Miller Electric MILLERMATIC 350P User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual