Millermatic 211 Auto-Set w/MVP - Gempler's · Millermatic 211 Auto-Set w/MVP ... distributor or...

Processes

OM-239 988J 201010

Arc Welding Power Source AndWire Feeder

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

File: MIG (GMAW)Visit our website atwww.MillerWelds.com

Millermatic 211Auto-Set w/MVP

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you dont have time to doit any other way.

Thats why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldnt afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,theres a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 200909

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 SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symboles utiliss 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7. . . . .

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

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

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

SECTION 3 SPECIFICATIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3-2. Duty Cycle And Overheating 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curves 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Installing Welding Gun 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Installing Work Clamp 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Work Cable Routing Inside Unit 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Process/Polarity Table 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Changing Polarity 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Installing Gas Supply 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Connecting 1-Phase Input Power For 230 VAC Input 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Electrical Service Guide For 230 VAC Input 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Extension Cord Data 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Serial Number And Rating Label Location 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. MultiVoltage Plug (MVP) Connection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Selecting A Location And Connecting Input Power 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Installing Wire Spool And Adjusting Hub Tension 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14. Threading Welding Wire 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15. Removing MIG Gun From Welding Power Source 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16. Connecting Spool Gun To Millermatic 211 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17. Cable Management Strap 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Power Switch 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Weld Parameter Chart 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE & TROUBLESHOOTING 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Overload Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Changing Drive Roll Or Wire Inlet Guide 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Troubleshooting Table 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 8 MIG WELDING (GMAW) GUIDELINES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1. Typical MIG Process Connections 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2. Typical MIG Process Control Settings 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3. Holding And Positioning Welding Gun 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4. Conditions That Affect Weld Bead Shape 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Gun Movement During Welding 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6. Poor Weld Bead Characteristics 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7. Good Weld Bead Characteristics 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8. Troubleshooting Excessive Spatter 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9. Troubleshooting Porosity 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Troubleshooting Excessive Penetration 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11. Troubleshooting Lack Of Penetration 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12. Troubleshooting Incomplete Fusion 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13. Troubleshooting Burn-Through 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-14. Troubleshooting Waviness Of Bead 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15. Troubleshooting Distortion 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16. Common MIG Shielding Gases 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17. Troubleshooting Guide For Semiautomatic Welding Equipment 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 PARTS LIST 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY

OM-239 988 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _201003

7

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

1-1. Symbol Usage

DANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICE Indicates statements not related to personal injury.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

Do not touch live electrical parts.

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

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

Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

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

unit. Additional safety precautions are required when any of the follow-

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

Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

When making input connections, attach proper grounding conduc-tor first double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directlywith a separate cable.

Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.

Do not touch electrode holders connected to two welding ma-chines at the same time since double open-circuit voltage will bepresent.

Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

Do not connect more than one electrode or work cable to anysingle weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of inputpower. Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

HOT PARTS can burn.

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

ment. To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

OM-239 988 Page 2

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use local forced ventilation at thearc to remove welding fumes and gases.

If ventilation is poor, wear an approved air-supplied respirator.

Read and understand the Material Safety Data Sheets (MSDSs)and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).

Wear approved safety glasses with side shields under yourhelmet.

Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistantmaterial (leather, heavy cotton, or wool) and foot protection.

ARC RAYS can burn eyes and skin.

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

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

WELDING can cause fire or explosion.

Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

Do not weld where the atmosphere may contain flammable dust,gas, or liquid vapors (such as gasoline).

Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

After completion of work, inspect area to ensure it is free of sparks,glowing embers, and flames.

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

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect ImplantedMedical Devices.

Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

Implanted Medical Device wearers should consult their doctorand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in

use or connected for use. Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

Read and follow instructions on compressed gas cylinders,associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.

OM-239 988 Page 3

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

FIRE OR EXPLOSION hazard.

Do not install or place unit on, over, or nearcombustible surfaces.

Do not install unit near flammables.

Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to lift andsupport unit.

If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.

Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94110) when manu-ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

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

starting to weld again. Do not block or filter airflow to unit.

FLYING SPARKS can injure.

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

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

Sparks can cause fires keep flammables away.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handlingboards or parts.

Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can injure.

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

rolls.

WELDING WIRE can injure.

Do not press gun trigger until instructed to doso.

Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can injure.

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

closed and securely in place.

Have only qualified persons remove doors, panels, covers, orguards for maintenance and troubleshooting as necessary.

Reinstall doors, panels, covers, or guards when maintenance isfinished and before reconnecting input power.

READ INSTRUCTIONS.

Read and follow all labels and the OwnersManual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

Use only genuine replacement parts from the manufacturer.

Perform maintenance and service according to the OwnersManuals, industry standards, and national, state, and localcodes.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

Have only qualified persons familiar withelectronic equipment perform this installation.

The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

If notified by the FCC about interference, stop using theequipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

Be sure all equipment in the welding area iselectromagnetically compatible.

To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-tronic equipment.

Be sure this welding machine is installed and groundedaccording to this manual.

If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

OM-239 988 Page 4

1-4. California Proposition 65 Warnings

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

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

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

For Gasoline Engines:

Engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproduc-tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birthdefects, and other reproductive harm.

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 Weldingand 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 Protec-tion 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 StandardW117.2, from Canadian Standards Association, Standards Sales, 5060Spectrum 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 Protec-tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork, 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, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(phone: 1-866-512-1800) (there are 10 OSHA Regional Officesphone for Region 5, Chicago, is 312-353-2220, website:www.osha.gov).U.S. Consumer Product Safety Commission (CPSC), 4330 East WestHighway, Bethesda, MD 20814 (phone: 301-504-7923, website:www.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation, The Na-tional Institute for Occupational Safety and Health (NIOSH), 1600Clifton 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 electricand magnetic fields (EMF). Welding current creates an EMF fieldaround the welding circuit and welding equipment. EMF fields may inter-fere with some medical implants, e.g. pacemakers. Protectivemeasures for persons wearing medical implants have to be taken. Forexample, access restrictions for passersby or individual risk assess-ment for welders. All welders should use the following procedures inorder to minimize exposure to EMF fields from the welding circuit:

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

2. Do not place your body between welding cables. Arrange cablesto 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 thewelding circuit as possible.

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

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 wirefeeder.

About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.

OM-239 988 Page 5

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

fre_som_2010037

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

2-1. Symboles utiliss

DANGER! Indique une situation dangereuse qui si onlvite pas peut donner la mort ou des blessures graves.Les dangers possibles sont montrs par les symbolesjoints ou sont expliqus dans le texte.

Indique une situation dangereuse qui si on lvite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrs par les symboles joints ousont expliqus dans le texte.

NOTE Indique des dclarations pas en relation avec des blessurespersonnelles.

Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGERDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECESCHAUDES. Consulter les symboles et les instructions ci-dessous yaffrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce ma-nuel pour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructionsen matire de scurit indiques ci-dessous ne constituentquun sommaire des instructions de scurit plus compltesfournies dans les normes de scurit numres dans la Sec-tion 2-5. Lire et observer toutes les normes de scurit.

Seul un personnel qualifi est autoris installer, faire fonc-tionner, entretenir et rparer cet appareil.

Pendant le fonctionnement, maintenir distance toutes lespersonnes, notamment les enfants de lappareil.

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr lasortie. Le circuit dalimentation et les circuits inter-nes de la machine sont galement sous tensionlorsque lalimentation est sur Marche. Dans le modede soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalli-ques en contact avec le fil sont sous tensionlectrique. Un quipement install ou mis la terrede manire incorrecte ou impropre constitue undanger.

Ne pas toucher aux pices lectriques sous tension.

Porter des gants isolants et des vtements de protection secs etsans trous.

Sisoler de la pice couper et du sol en utilisant des housses oudes tapis assez grands afin dviter tout contact physique avec lapice couper ou le sol.

Ne pas se servir de source lectrique courant lectrique dans leszones humides, dans les endroits confins ou l o on risque detomber.

Se servir dune source lectrique courant lectrique UNIQUE-MENT si le procd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savrencessaire, se servir de la fonction de tlcommande si lappareilen est quip.

Dautres consignes de scurit sont ncessaires dans les condi-tions suivantes : risques lectriques dans un environnementhumide ou si lon porte des vtements mouills ; sur des structuresmtalliques telles que sols, grilles ou chafaudages ; en positioncoince comme assise, genoux ou couche ; ou sil y a un risquelev de contact invitable ou accidentel avec la pice souder oule sol. Dans ces conditions, utiliser les quipements suivants,

dans lordre indiqu : 1) un poste souder DC tension constante( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste souder AC tension vide rduite. Dans la plupart des situations,lutilisation dun poste souder DC fil tension constante est re-commande. En outre, ne pas travailler seul !

Couper lalimentation ou arrter le moteur avant de procder lin-stallation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-mes de scurit).

Installer le poste correctement et le mettre la terre convenable-ment selon les consignes du manuel de loprateur et les normesnationales, provinciales et locales.

Toujours vrifier la terre du cordon dalimentation. Vrifier etsassurer que le fil de terre du cordon dalimentation est bienraccord la borne de terre du sectionneur ou que la fiche ducordon est raccorde une prise correctement mise la terre.

En effectuant les raccordements dentre, fixer dabord le conduc-teur de mise la terre appropri et contre-vrifier les connexions.

Les cbles doivent tre exempts dhumidit, dhuile et de graisse;protgezles contre les tincelles et les pices mtalliqueschaudes.

Vrifier frquemment le cordon dalimentation afin de sassurerquil nest pas altr ou nu, le remplacer immdiatement sil lest.Un fil nu peut entraner la mort.

Lquipement doit tre hors tension lorsquil nest pas utilis.

Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-sante ou mal pisss.

Ne pas enrouler les cbles autour du corps.

Si la pice soude doit tre mise la terre, le faire directementavec un cble distinct.

Ne pas toucher llectrode quand on est en contact avec la pice,la terre ou une lectrode provenant dune autre machine.

Ne pas toucher des porte lectrodes connects deux machinesen mme temps cause de la prsence dune tension vide dou-ble.

Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conform-ment ce manuel.

Porter un harnais de scurit si lon doit travailler au-dessus du sol.

Sassurer que tous les panneaux et couvercles sont correctementen place.

Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec la pice souder ou la table de travail, le plus prs pos-sible de la soudure.

Isoler la pince de masse quand pas mis la pice pour viter lecontact avec tout objet mtallique.

Ne pas raccorder plus dune lectrode ou plus dun cble demasse une mme borne de sortie de soudage.

OM-239 988 Page 6

Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur UNE FOISlalimentation coupe. Arrter les convertisseurs, dbrancher le courant lectrique et

dcharger les condensateurs dalimentation selon les instructionsindiques dans la partie Entretien avant de toucher les pices.

LES PICES CHAUDES peuventprovoquer des brlures.

Ne pas toucher mains nues les partieschaudes.

Prvoir une priode de refroidissement avant detravailler lquipement.

Ne pas toucher aux pices chaudes, utiliser les outils recomman-ds et porter des gants de soudage et des vtements pais pourviter les brlures.

LES FUMES ET LES GAZ peuventtre dangereux.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

Eloigner votre tte des fumes. Ne pas respirer les fumes.

lintrieur, ventiler la zone et/ou utiliser une ventilation force auniveau de larc pour lvacuation des fumes et des gaz desoudage.

Si la ventilation est mdiocre, porter un respirateur anti-vapeursapprouv.

Lire et comprendre les spcifications de scurit des matriaux(MSDS) et les instructions du fabricant concernant les mtaux, lesconsommables, les revtements, les nettoyants et les dgrais-seurs.

Travailler dans un espace ferm seulement sil est bien ventil ouen portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes etdes gaz de soudage peuvent dplacer lair et abaisser le niveaudoxygne provoquant des blessures ou des accidents mortels.Sassurer que lair de respiration ne prsente aucun danger.

Ne pas souder dans des endroits situs proximit doprationsde dgraissage, de nettoyage ou de pulvrisation. La chaleur etles rayons de larc peuvent ragir en prsence de vapeurs et for-mer des gaz hautement toxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soitbien ventil, et en portant un respirateur alimentation dair. Lesrevtements et tous les mtaux renfermant ces lments peuventdgager des fumes toxiques en cas de soudage.

LES RAYONS DE LARC peuventprovoquer des brlures dans lesyeux et sur la peau.Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brluredans les yeux et sur la peau. Des tincelles sont projetes pendant lesoudage.

Porter un casque de soudage approuv muni de verres filtrantsappropri pour protger visage et yeux pour protger votre visageet vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1et Z87.1 numr dans les normes de scurit).

Porter des lunettes de scurit avec crans latraux mme sousvotre casque.

Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissementset les tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

Porter des vtements confectionns avec des matires rsistan-tes et ignifuges (cuir, coton lourd ou laine) et des bottes deprotection.

LE SOUDAGE peut provoquer unincendie ou une explosion.Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent

tre projetes de larc de soudure. La projection dtincelles, despices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avecdes objets mtalliques peut provoquer des tincelles, une explosion,un surchauffement ou un incendie. Avant de commencer le soudage,vrifier et sassurer que lendroit ne prsente pas de danger.

Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit les recouvrirsoigneusement avec des protections homologus.

Ne pas souder dans un endroit l o des tincelles peuvent tombersur des substances inflammables.

Se protger et dautres personnes de la projection dtincelles etde mtal chaud.

Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

Surveiller tout dclenchement dincendie et tenir un extincteur proximit.

Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

Ne pas effectuer le soudage sur des conteneurs ferms tels quedes rservoirs, tambours, ou conduites, moins quils naient tprpars correctement conformment AWS F4.1 (voir les nor-mes de scurit).

Ne soudez pas si lair ambiant est charg de particules, gaz, ou va-peurs inflammables (vapeur dessence, par exemple).

Brancher le cble de masse sur la pice le plus prs possible de lazone de soudage pour viter le transport du courant sur unelongue distance par des chemins inconnus ventuels en provo-quant des risques dlectrocution, dtincelles et dincendie.

Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sansrevers, des chaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos po-ches telles quun allumeur au butane ou des allumettes.

Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux chaud et avoir de la surveillance et unextincteur proximit.

DES PIECES DE METAL ou DESSALETES peuvent provoquer desblessures dans les yeux.

Le soudage, lcaillement, le passage de la pice la brosse enfil de fer, et le meulage gnrent des tincelles et des particulesmtalliques volantes. Pendant la priode de refroidissement dessoudures, elles risquent de projeter du laitier.

Porter des lunettes de scurit avec crans latraux ou un cranfacial.

OM-239 988 Page 7

LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort. Fermer lalimentation du gaz protecteur en cas

de non-utilisation. Veiller toujours bien arer les espaces confi-

ns ou se servir dun respirateur dadductiondair homologu.

Les CHAMPS LECTROMAGNTIQUES (CEM)peuvent affecter les implants mdicaux.

Les porteurs de stimulateurs cardiaqueset autres implants mdicaux doivent rester distance.

Les porteurs dimplants mdicaux doivent consulterleur mdecin et le fabricant du dispositif avant de sapprocherde la zone o se droule du soudage larc, du soudagepar points, du gougeage, de la dcoupe plasmaou une opration de chauffage par induction.

LE BRUIT peut endommager loue.

Le bruit des processus et des quipements peutaffecter loue.

Porter des protections approuves pour lesoreilles si le niveau sonore est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endom-mage, elle peut exploser. Du fait que les bouteillesde gaz font normalement partie du procd de

soudage, les manipuler avec prcaution.

LES BOUTEILLES peuvent explosersi elles sont endommages.

Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, des dommages physiques, du laitier, desflammes ouvertes, des tincelles et des arcs.

Placer les bouteilles debout en les fixant dans un support station-naire ou dans un porte-bouteilles pour les empcher de tomber oude se renverser.

Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

Ne jamais placer une torche de soudage sur une bouteille gaz.

Une lectrode de soudage ne doit jamais entrer en contact avecune bouteille.

Ne jamais souder une bouteille pressurise risque dexplosion.

Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,tuyaux et raccords convenables pour cette application spcifique ;les maintenir ainsi que les lments associs en bon tat.

Dtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

Le couvercle du dtendeur doit toujours tre en place, sauf lorsquela bouteille est utilise ou quelle est relie pour usage ultrieur.

Utiliser les quipements corrects, les bonnes procdures et suffi-samment de personnes pour soulever et dplacer les bouteilles.

Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scu-rit.

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OUDEXPLOSION. Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables. Ne pas installer lappareil proximit de pro-

duits inflammables.

Ne pas surcharger linstallation lectrique sassurer quelalimentation est correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LQUIPEMENT peutprovoquer des blessures. Utiliser lanneau de levage uniquement pour

soulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

Tenir lquipement (cbles et cordons) distance des vhiculesmobiles lors de toute opration en hauteur.

Suivre les consignes du Manuel des applications pour lquationde levage NIOSH rvise (Publication N94110) lors du levagemanuelle de pices ou quipements lourds.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT. Prvoir une priode de refroidissement ; res-

pecter le cycle opratoire nominal. Rduire le courant ou le facteur de marche

avant de poursuivre le soudage.

Ne pas obstruer les passages dair du poste.

LES TINCELLES PROJETESpeuvent provoquer des blessures.

Porter un cran facial pour protger le visage etles yeux.

Affter llectrode au tungstne uniquement lameuleuse dote de protecteurs. Cettemanuvre est excuter dans un endroit srlorsque lon porte lquipement homologu deprotection du visage, des mains et du corps.

Les tincelles risquent de causer un incendie loigner toute sub-stance inflammable.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.

tablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

Utiliser des pochettes et des botes antista-tiques pour stocker, dplacer ou expdier descartes de circuits imprimes.

OM-239 988 Page 8

Les PICES MOBILES peuventcauser des blessures. Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures. Ne pas appuyer sur la gchette avant den

avoir reu linstruction. Ne pas diriger le pistolet vers soi, dautres

personnes ou toute pice mcanique enengageant le fil de soudage.

Les PICES MOBILES peuventcauser des blessures. Sabstenir de toucher des organes mobiles tels

que des ventilateurs. Maintenir ferms et verrouills les portes,

panneaux, recouvrements et dispositifs deprotection.

Lorsque cela est ncessaire pour des travaux dentretien et dedpannage, faire retirer les portes, panneaux, recouvrementsou dispositifs de protection uniquement par du personnel qua-lifi.

Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS.

Lire et appliquer les instructions sur lestiquettes et le Mode demploi avant linstal-lation, lutilisation ou lentretien de lappareil.Lire les informations de scurit au dbut dumanuel et dans chaque section.

Nutiliser que les pices de rechange recommandes par leconstructeur.

Effectuer lentretien en respectant les manuels dutilisation, lesnormes industrielles et les codes nationaux, dtat et locaux.

LE RAYONNEMENT HAUTEFRQUENCE (H.F.) risque deprovoquer des interfrences.

Le rayonnement haute frquence (H.F.) peutprovoquer des interfrences avec les qui-pements de radionavigation et de com-munication, les services de scurit et les ordi-nateurs.

Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstalla-tion.

Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences rsultant de linstallation.

Si le FCC signale des interfrences, arrter immdiatement lap-pareil.

Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs une distan-ce correcte et utiliser une terre et un blindage pour rduire lesinterfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.

Lnergie lectromagntique risque deprovoquer des interfrences pour lquipementlectronique sensible tel que les ordinateurs etlquipement command par ordinateur tel queles robots.

Veiller ce que tout lquipement de la zone de soudage soitcompatible lectromagntiquement.

Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation de c-bles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiquesdont ltat de Californie reconnat quils provoquent des mal-formations congnitales et, dans certains cas, des cancers.(Code de sant et de scurit de Californie, chapitre 25249.5et suivants)

Les batteries, les bornes et autres accessoires contiennentdu plomb et des composs base de plomb, produits chimi-ques dont ltat de Californie reconnat quils provoquent descancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs manipu-lation.

Ce produit contient des produits chimiques, notamment duplomb, dont ltat de Californie reconnat quils provoquent

des cancers, des malformations congnitales ou dautresproblmes de procration. Se laver les mains aprsutilisation.

Pour les moteurs essence :

Les gaz dchappement des moteurs contiennent des pro-duits chimiques dont ltat de Californie reconnat quilsprovoquent des cancers et des malformations congnitalesou autres problmes de procration.

Pour les moteurs diesel :

Les gaz dchappement des moteurs diesel et certains deleurs composants sont reconnus par ltat de Californie com-me provoquant des cancers et des malformationscongnitales ou autres problmes de procration.

OM-239 988 Page 9

2-5. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, de GlobalEngineering Documents (tlphone : 1-877-413-5184, site internet :www.global.ihs.com).National Electrical Code, NFPA Standard 70, de National Fire Protec-tion Association, Quincy, MA 02269 (tlphone : 800-344-3555, siteInternet : 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, Chan-tilly, VA 20151 (tlphone : 703-788-2700, site Internet :www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, de Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (tlphone :800-463-6727, site internet : www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, de American National Standards Institute,

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

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, de National Fire Protection Association,P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000,site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for GeneralIndustry, Title 29, Code of Federal Regulations (CFR), Part 1910,Subpart Q, and Part 1926, Subpart J, de U.S. Government PrintingOffice, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureauxrgionauxle tlphone de la rgion 5, Chicago, est 312-353-2220, siteInternet : www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East WestHighway, Bethesda, MD 20814 (tlphone : 301-504-7923, site inter-net : www.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation, TheNational Institute for Occupational Safety and Health (NIOSH), 1600Clifton Rd, Atlanta, GA 30333 (tl[hone : 1-800-232-4636, site internet:www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant lectrique qui traverse tout conducteur gnre des champslectromagntiques (CEM) certains endroits. Le courant de soudagecre un CEM autour du circuit et du matriel de soudage. Les CEMpeuvent crer des interfrences avec certains implants mdicauxcomme des stimulateurs cardiaques. Des mesures de protection pourles porteurs dimplants mdicaux doivent tre prises: par exemple, desrestrictions daccs pour les passants ou une valuation individuelledes risques pour les soudeurs. Tous les soudeurs doivent appliquer lesprocdures suivantes pour minimiser lexposition aux CEM provenantdu circuit de soudage:

1. Rassembler les cbles en les torsadant ou en les attachant avecdu ruban adhsif ou avec une housse.

2. Ne pas se tenir au milieu des cbles de soudage. Disposer lescbles dun ct et distance de loprateur.

3. Ne pas courber et ne pas entourer les cbles autour de votrecorps.

4. Maintenir la tte et le torse aussi loin que possible du matriel ducircuit de soudage.

5. Connecter la pince sur la pice aussi prs que possible de lasoudure.

6. Ne pas travailler proximit dune source de soudage, nisasseoir ou se pencher dessus.

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

En ce qui concerne les implants mdicaux :

Les porteurs dimplants doivent dabord consulter leur mdecin avantde sapprocher des oprations de soudage larc, de soudage parpoints, de gougeage, du coupage plasma ou de chauffage par induc-tion. Si le mdecin approuve, il est recommand de suivre lesprocdures prcdentes.

OM-239 988 Page 10

A complete Parts List is available on-line at www.MillerWelds.com

OM-239 988 Page 11

SECTION 3 SPECIFICATIONS3-1. Specifications

A. 120 VAC w/AutoSet

Rated WeldingOutput Amperage Range

MaximumOpen-CircuitVoltage DC

Amperes Input atRated Load Out-put 120 V, 60 Hz,

Single-Phase

KVA KWWeightW/ Gun

Overall Dimensions

90 A @ 20Volts DC, 20%

Duty Cycle30 140 30 20 2.9 2.5

74 lb(34 kg)

Length: 17-1/2 in.(444 mm)

Width: 10-5/8 in.(273 mm)

Height: 15-3/4 in.(400 mm)

Wire TypeAnd Dia

Solid Stainless Flux Cored Wire Feed Speed Range

.024 - .035 in.(0.6 - 0.9

mm)

.023 - .035 in.(0.6 - 0.9

mm)

.030 - .035 in.(0.8 - 0.9 mm)

80 565 IPM (2.0 14.4 m/min) At No Load60 440 IPM (1.5 11.2 m/min) Feeding Wire

B. 230 VAC w/AutoSet

Rated WeldingOutput

AmperageRange

Maximum Open-Circuit Voltage

DC

Amperes Input atRated Load Output

230 V, 60 Hz,Single-Phase

KVA KWWeightW/ Gun

Overall Dimensions

150 A @ 23.5 VoltsDC, 30% Duty Cycle

At 60 Hz Input30 210 34 24.3 5.5 4.75

74 lb(34 kg)

Length: 17-1/2 in.(444 mm)

Width: 10-5/8 in.(273 mm)

Height: 15-3/4 in.(400 mm)

Wire TypeAnd Dia

Solid/Stainless

Flux CoredWire Feed Speed Range

.024 .035 in.(0.6 0.9 mm)

.030 .045 in.(0.8 1.2 mm)

80 565 IPM (2.0 14.4 m/min) At No Load60 440 IPM (1.5 11.2 m/min) Feeding Wire


OM-239 988 Page 12

3-2. Duty Cycle And Overheating

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

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.

NOTICE Exceeding duty cyclecan damage unit and void warranty.

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutesduty1 4/95 284 313-A

A. 120 VACInput

B. 230 VACInput

3 Minutes Welding 7 Minutes Resting

20% duty cycle at 90 amps

30% duty cycle at 150 amps, 60 Hz

2 Minutes Welding 8 Minutes Resting


OM-239 988 Page 13

3-3. Volt-Ampere Curves

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown.

240 580-A

A. 120 VAC Input

B. 230 VAC Input

0

5

10

15

20

25

30

10 20 30 40 50 60 70 80 90 100 110 120 130 140

VO

LT

AG

E

AMPERAGE

MAXMIN

0

5

10

15

20

25

30

35

10 30 50 70 90 110 130 150 170 190 210 230

VO

LT

AG

E

AMPERAGE

MAX

MIN

0

0


OM-239 988 Page 14

SECTION 4 INSTALLATION4-1. Installing Welding Gun

Ref. 802 982-A / Ref. 243 861-A / Ref. 801 987

1 Drive Assembly

2 Gun Securing Knob

3 Gun End

Loosen knob. Insert end of gunthrough opening in front paneluntil it bottoms against driveassembly. Tighten knob.

4 Gun Trigger Plug

Insert into receptacle, and tightenthreaded collar.

Close door.

Correct Incorrect

Be sure that gun end is tight against drive assembly.

3 3

21

4

3

4-2. Installing Work Clamp

Tighten connection hardwarewith proper tools. Do not justhand tighten hardware. A looseelectrical connection will causepoor weld performance and ex-cessive heating of the workclamp.

1 Work Clamp

2 Work Cable From Unit

3 Screw

4 Flat Washer5 Lock Washer

6 Nut

Route work cable through hole inclamp handle. Secure cable withhardware as shown.

805 460-A

2

6

1

Tools Needed:

7/16 in.

7/16 in

3

4

5


OM-239 988 Page 15

4-3. Work Cable Routing Inside Unit

Ref. 802 982-A

1 Work Cable

2 Output Terminal Block

Insert work cable through openingin front panel and route along backof front panel to output terminalblock.

Close door.

2

1

4-4. Process/Polarity Table

Process PolarityCable Connections

Cable To Gun Cable To Work

GMAW Solid wire with shield-ing gas

DCEP Reverse polarity Connect to positive (+) out-put terminal

Connect to negative () outputterminal

FCAW Self-shielding wire no shielding gas

DCEN Straight Polarity Connect to negative ()output terminal

Connect to positive (+) outputterminal

4-5. Changing Polarity

1 Lead Connections For DirectCurrent Electrode Positive(DCEP)

2 Lead Connections For DirectCurrent Electrode Negative(DCEN)

Always read and follow wiremanufacturers recommendedpolarity, and see Section 4-4.

Close door.

1

Ref. 203 501 / Ref. 802 982-

2

C H A N G IN G P O L A R IT YDCEP

Electrode POSITIVEFOR SOLID WIRE

DCENElectrode Negative

Flux Core WireWorkClampLead

Wire DriveLead

WorkClampLead

Wire DriveLead

C H A N G IN G P O L A R IT YDCEP

Electrode PositiveFOR SOLID WIRE

DCENElectrode Negative

Flux Core WireWorkClampLead

Wire DriveLead

WorkClampLead

Wire DriveLead

Connection hardware must be tightened with proper tools. Do notjust hand tighten hardware. A loose electrical connection will causepoor weld performance and excessive heating at the terminal block.


OM-239 988 Page 16

4-6. Installing Gas Supply

Obtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter GasHose Connection

6 Welding Power Source GasHose Connection

Connect supplied gas hosebetween regulator/flowmeter gashose connection, and fitting on rearof welding power source.

7 Flow Adjust

Flow rate should be set when gas isflowing through welding powersource and welding gun. Openfeed-head pressure assembly sothat wire will not feed. Press guntrigger to start gas flow.

Typical flow rate is 20 cfh (cubicfeet per hour). Check wiremanufacturers recommendedflow rate.

After flow is set, close feedheadpressure assembly.

Tools Needed:

Ref. 802 028 / 805 389-A / Ref. 802 982-A / Ref. 243 861-A

5/8, 1-1/8 in.

1

2

3

Argon Gas OrMixed Gas

4

5

7

DO NOT use Argon/Mixed gas regulator/flowmeterwith CO2 shielding gas. See Parts List for optionalCO2 gas regulator/flowmeter and hose.

6

Feedhead Pressure Assembly Open

Feedhead Pressure Assembly Closed


OM-239 988 Page 17

4-7. Connecting 1-Phase Input Power For 230 VAC Input

803 766-B / Ref. 802 443-A

! Installation must meet all Nationaland Local Codes have onlyqualified persons make thisinstallation.

! Disconnect and lockout/tagoutinput power before connectinginput conductors from unit.

! Always connect green or green/yellow conductor to supplygrounding terminal first, and neverto a line terminal.

1 Black And White Input Conductor(L1 And L2)

2 Green Or Green/Yellow GroundingConductor

3 Input Power Cord.

4 Disconnect Device (switch shown inthe OFF position)

5 Disconnect Device GroundingTerminal

6 Disconnect Device Line Terminals

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1 and L2 todisconnect device line terminals.

7 Over-Current Protection

Select type and size of over-currentprotection using Section 4-8 (fuseddisconnect switch shown).

8 Receptacle (NEMA 6-50R)Customer Supplied

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

4

3

L1L2

1

=GND/PE Earth Ground

2

1

5

6

7

Tools Needed:

L1L2

230 VAC, 1

8


OM-239 988 Page 18

4-8. Electrical Service Guide For 230 VAC Input

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

60 HzSinglePhase

Input Voltage (V) 230

Input Amperes (A) At Rated Output 24.3

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses 2 25

Normal Operating Fuses 3 35

Min Input Conductor Size In AWG 4 14

Max Recommended Input Conductor Length In Feet (Meters)53

(16)

Min Grounding Conductor Size In AWG 4 14

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.

4-9. Extension Cord Data

When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.

Input VoltageInput Power

Phase Hertz Conductor Size Max. Cord Length

120 V 1 60 14 AWG 27 ft (8 m)

230 V 1 60 14 AWG 53 ft (16 m)


OM-239 988 Page 19

4-10. Serial Number And Rating Label LocationThe 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.

4-11. MultiVoltage Plug (MVP) Connection

Selecting Plug

1 Power Cord Connector FromWelding Power Source

Select plug for power supply receptacleavailable at site. Not all plugs shown areprovided as standard with unit.

2 Plug NEMA Type 515P

3 Receptacle NEMA Type 515R(Customer Supplied)

4 Plug NEMA Type 520P (Optional)5 Receptacle NEMA Type 520R

(Customer Supplied)6 Plug NEMA Type 650P7 Receptacle NEMA Type 650R

(Customer Supplied)

! Follow electrical service guide for230 VAC in Section 4-8. Do not useplug rating to size branch circuitprotection.

Connecting Plug To Power Cord

Align arrow on plug with arrow on powercord connector. Push together.

Tighten threaded collar. As threaded collaris tightened, push plug onto adapter untilcollar is completely tight.

Connect plug to receptacle.

MVP Plug1 201010 / Ref. 805 390-C

! Do not cut off power cord con-nector and rewire. The powercord connector and plugs willwork with standard NEMA re-ceptacles. Modifying powercord, connector, and plugs willvoid product warranty.

3

2

7

4

5

6

1

Selecting Plug

Connecting Plug To Power Cord


OM-239 988 Page 20

4-12. Selecting A Location And Connecting Input Power

! Do Not cut off power cord connec-tor and rewire. The power cord con-nector and plugs will work withstandard NEMA receptacles. Modi-fying power cord, connector, andplugs will void product warranty.

! Special installation may be requiredwhere gasoline or volatile liquidsare present see NEC Article 511 orCEC Section 20.

For 120 volts AC input power, a 20 ampereindividual branch circuit protected bytime-delay fuses or circuit breaker isrequired. For 230 volts AC input power, seeSection 4-7.

1 Power Cord Connector

2 Plug NEMA Type 5-15P

3 Receptacle NEMA Type 5-15R(Customer Supplied)

4 Plug NEMA Type 5-20P (Optional)

5 Receptacle NEMA Type 5-20R(Customer Supplied)

6 Plug NEMA Type 6-50P7 Receptacle NEMA Type 6-50R

(Customer Supplied)

Select plug for power supply receptacleavailable at site. Install plug onto powercord adapter. As threaded collar istightened, push plug onto adapter untilcollar is completely tight.

Connect plug to receptacle.

18 in. (457 mm) ofspace for airflow

! Do not move or operate unitwhere it could tip.

805 390-C

3

5

7

2

4

6

1


OM-239 988 Page 21

4-13. Installing Wire Spool And Adjusting Hub Tension

When a slight force is neededto turn spool, tension is set.

1/2 in.

Tools Needed:

803 012 / 803 013 -B / Ref. 802 444-C

Installing 8 in. (203 mm) Wire Spool

Installing 4 in. (102 mm) Wire Spool

When a slight force isneeded to turn spool, ten-sion is set.

Retaining ring used with 8in. (203 mm) spool only.

Adapter used with 8 in.(203 mm) spool only.

Align locking hole inspool with lockingpin on spool hub.


OM-239 988 Page 22

4-14. Threading Welding Wire

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll

6 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

Pull and hold wire; cut off end.

Remove gun nozzle and contact tip.

Open pressure assembly. Push wire thru guides into gun;continue to hold wire.

Be sure that wire is positioned in proper driveroll groove and wire is laying in the groove.

Hold wire tightly to keep itfrom unraveling.

Ref. 802 982-A / Ref. 205 837 / Ref. 243 861-A

WOOD

Feed wire to check drive roll pressure.Tighten knob enough to prevent slipping.

Cut off wire. Close door.

Press gun trigger until wire comesout of gun. (Keep gun cable asstraight as possible.)

Be sure that tip matches wire diameter.Reinstall contact tip and nozzle.

Turn power on.

INPUTPOWER

Tighten

1234

Use pressure indicator scale to set a desireddrive roll pressure. Begin with a setting of 3.If necessary, make additional adjustmentsafter trying this initial setting.

PressureIndicator

Scale

Tighten

1234

6 in(150 mm)

Close and tighten pressure assembly, and let go of wire.

1 2 3

4

56

7 8 9

6

1 3

4

52

4 in.(102 mm)


OM-239 988 Page 23

4-15. Removing MIG Gun From Welding Power Source

Open Pressure Assembly

Hold wire tightly to keep itfrom unraveling.

Rewind Wire Onto Spool, FastenEnd Of Wire To Spool

Cut Off End Of Wire

Loosen Knob, Disconnect Gun TriggerPlug, And Pull Gun From Unit

Ref. 802 982-A / Ref. 243 861-A

Knob


OM-239 988 Page 24

4-16. Connecting Spool Gun To Millermatic 211

Ref. 804 984-A / Ref. 805 390-A / Ref. 801 987

1 Drive Assembly

2 Spool Gun

3 Gun Securing Knob

4 Gun End

Loosen thumbscrew. Insert endthrough opening until it bottomsagainst drive assembly. Tightengun securing knob.

Spool gun must be insertedcompletely to prevent leakage ofshielding gas.

5 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

6 Polarity Changeover TerminalBlock

To make proper polarity connection,see Section 4-5.

7 MIG Gun/Spool Gun Switch

Place switch in Spool Gun position.

Close door.

Incorrect

Gun Fully SeatedGun Not SeatedCorrect

Be sure that gun end is tight against drive assembly.

44

Exposed O-ringswill cause shielding

gas leakage.

5

6

1 3 24

7


OM-239 988 Page 25

4-17. Cable Management Strap

805 392-B

1 Cable Management Strap

Coil power cable and work cable, andsecure to unit using the cablemanagement strap.

1


OM-239 988 Page 26

SECTION 5 OPERATION

5-1. Controls

1 Wire Speed Control

Turn control clockwise inside white scale(10-100) to increase wire feed speed. (seeweld parameter chart in welding powersource or Section 5-3).

2 Voltage Control

Turn control clockwise inside white scale(1-10) to increase voltage (see weldparameter chart in welding power sourceor Section 5-3).

3 MIG Gun/Spool Gun SwitchSwitch allows selecting either a MIG gun ora spool gun depending on the type of gunconnected to the unit.4 Over Temperature LightIf unit overheats, light flashes and outputstops. Allow unit to cool before resumingoperation.5 Gun Trigger Receptacle6 AutoSet LightTo use AutoSet mode, rotate WireSpeed control inside blue/green area forthe applicable Weld Wire Diameter,

AutoSet light will turn on, and the unit willprovide the appropriate wire feed speed forthe material thickness selected using theVoltage control (see Section 5-3).

Rotate Voltage control inside blue/greenscale (24 ga to 3/8) for the applicablematerial thickness and the unit will providethe appropriate voltage within the range of theselected material thickness and the selectedWeld Wire Diameter (see Section 5-3).

Blue shaded areas are for .035 wireapplications. Green shaded areas arefor .030 wire applications.

Ref. 239 991-B

1

2

3

45

6


OM-239 988 Page 27

5-2. Power Switch

805 389-A

1 Power Switch

The power switch also functions assupplementary protector CB1 (seeSection 6-2).

1


OM-239 988 Page 28

5-3. Weld Parameter Chart

239 992-C


OM-239 988 Page 29

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

! Disconnect power before maintaining.

Maintain more oftenduring severe conditions.

= Check = Change = Clean = Replace* To be done by Factory Authorized Service Agent

Reference

Every3Months

Unreadable Labels Weld Terminals Weld Cables

Every6Months

OR

Inside Unit

6-2. Overload Protection

805 389-A

1 Supplementary Protector CB1

The power switch also functions assupplementary protector CB1.

CB1 protects unit from overload. IfCB1 opens, unit shuts down.

Reset power switch/supplementaryprotector.

1

6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection

A. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, cycle unit poweroff and back on again.

B. Tip Saver/Short Circuit Protection

The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contacttip is shorted to workpiece, the unit shuts down the welding output, but the fan continues to run. To resume operation,release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun trigger, turn off unit, andremove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.


OM-239 988 Page 30

6-4. Changing Drive Roll Or Wire Inlet Guide

1 Inlet Wire Guide

Remove guide by pressing onbarbed area or cutting off one endnear housing and pulling it out ofhole. Push new guide into hole fromrear until it snaps in place.

2 Drive Roll

The drive roll consists of two differ-ent sized grooves. The stampedmarkings on the end surface of thedrive roll refers to the groove on theopposite side of the drive roll. Thegroove closest to the motor shaft isthe proper groove to thread (seeSection 4-14).

3 Retaining Pin

To secure drive roll, locate open slotand push drive roll completely overretaining pin, then rotate drive roll1/4 turn to closed slot.

2

1

3

802 984

.024 Groove.030/.035 Groove

Stamped .024 Stamped .030/.035


OM-239 988 Page 31

6-5. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed; fandoes not run.

Secure power cord plug in receptacle (see Section 4-12).

Replace building line fuse or reset circuit breaker if open.

Place Power switch in On position (see Section 5-2).

Reset welding power source supplementary protector if open (see Section 6-2).

No weld output; wire does not feed; fanmotor continues to run.

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes whenunit has cooled (see Section 3-2).

Secure gun trigger plug (see Section 4-1).

Release gun trigger and cycle unit power off and back on again.

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

Replace contact tip (see gun Owners Manual).

Check for proper polarity connections (see Section 4-5).

Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Place Power switch in On position (see Section 5-2).

Electrode wire feeding stops duringwelding.

Straighten gun cable and/or replace damaged parts.

Adjust drive roll pressure (see Section 4-14).

Change to proper drive roll groove (see Section 6-4).

Readjust hub tension (see Section 4-13).

Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.

Replace contact tip if blocked (see gun Owners Manual). Oversized tip may be required for some wires.

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 6-4 or gun Owners Manual).

Replace drive roll or pressure bearing if worn or slipping (see Section 6-4).

Secure gun trigger plug (see Section 4-1).

Check and clear any restrictions at drive assembly and liner (see Section 6-4 or gun Owners Manual).

Release gun trigger and allow gun and motor protection circuitry to reset.

Have nearest Factory Authorized Service Agent check drive motor.

OM-239 988 Page 32

SECTION 7 ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram

OM-239 988 Page 33

249 839-A

OM-239 988 Page 34

SECTION 8 MIG WELDING (GMAW) GUIDELINES

mig1 200912

Wire Feeder/Power Source

Workpiece

Gun

Regulator/Flowmeter

Gas

Shielding Gas

Work Clamp

8-1. Typical MIG Process Connections

! Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

Ref. 801 909-A

OM-239 988 Page 35

8-2. Typical MIG Process Control Settings

These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be surethey comply to specifications.

3.5 x 125 A = 437 ipm

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

30 90 A

40 145 A

50 180 A

Convert MaterialThickness toAmperage (A)

Material thickness determines weldparameters.

.035 in

Recommendation Wire Speed(Approx.)

1/8 or 0.125 in.

(0.001 in. = 1 ampere)0.125 in. = 125 A

Wire Size Amperage Range

0.023 in.

0.030 in.

0.035 in.

Select Wire Size

WireSize

0.023 in.

0.030 in.

0.035 in.

3.5 in. per ampere

2 in. per ampere

1.6 in. per ampere

Select Wire Speed(Amperage)

125 A based on 1/8 in.material thickness

ipm = inches per minute

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Select Voltage

Voltage controls height andwidth of weld bead.

Wire speed (amperage) controls weldpenetration (wire speed = burn-off rate)

OM-239 988 Page 36

8-3. Holding And Positioning Welding Gun

Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm)past end of nozzle, and tip of wire is positioned correctly on seam.

1 Hold Gun and Control GunTrigger

2 Workpiece

3 Work Clamp

4 Electrode Extension (Stickout)1/4 to 1/2 in. (6 To 13 mm)

5 Cradle Gun and Rest Hand onWorkpiece

23

5

4

90 90

0-15

45

45

1

0-15

S-0421-A

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

End View of Work Angle Side View of Gun Angle

FILLET WELDS

OM-239 988 Page 37

8-4. Conditions That Affect Weld Bead Shape

Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed(weld current), and voltage.

Slow

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

ELECTRODE EXTENSIONS (STICKOUT)

GUN ANGLES AND WELD BEAD PROFILES

10

10

GUN TRAVEL SPEEDS-0634

Push

Perpendicular Drag

Short Normal Long

Short Normal Long

Normal Fast

OM-239 988 Page 38

8-5. Gun Movement During Welding

Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,a weave bead or multiple stringer beads works better.

1 Stringer Bead SteadyMovement Along Seam

2 Weave Bead Side To SideMovement Along Seam

3 Weave Patterns

Use weave patterns to cover a widearea in one pass of the electrode.

S-0054-A

3

1 2

8-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

5

42 3

1

S-0053-A

8-7. Good Weld Bead Characteristics

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater DuringWelding

Weld a new bead or layer for each1/8 in. (3.2 mm) thickness in metalsbeing welded.

4 No Overlap

5 Good Penetration into BaseMetal

S-0052-B

2 3

1

4

5

OM-239 988 Page 39

8-8. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles thatcool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

8-9. Troubleshooting Porosity

Porosity small cavities or holes resulting from gas pocketsin weld metal.

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

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