Millermatic 350 AndMillermatic 350P

Processes

Description

Arc Welding Power Source

and Wire Feeder

OM-1327 213 814AD201004

MIG (GMAW) Welding

Pulsed MIG (GMAW-P)

Flux Cored (FCAW) Welding

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

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 9001:2000 QualitySystem Standard.

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 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-1327 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 indisconnect 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 workpieceor worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to preventcontact 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.

OM-1327 Page 2

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

FUMES AND GASES can be hazardous.

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-1327 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-1327 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-1327 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-1327 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-1327 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-1327 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-1327 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-1327 Page 10

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OM-1327 Page 11

SECTION 3 INSTALLATION

3-1. Specifications

Rated OutputMax. Open

CircuitVoltage

60 HzAmps Input at Rated Output

200 V 230 V 460 V 575V KVA KW

300 A at32 VDC,60% DutyCycle

350 A at32 VDC,40% DutyCycle

90Single-Phase

69(1.7*)

61(1.5*)

30(0.75*)

24(0.5*)

13.1 11.2

Three-Phase34(1.7*)

30(1.5*)

15(0.75*)

12(0.5*)

11.6 11.5

* While idling

Wire Type and Diameter Wire Feed Speed Dimensions Net Weight

Solid Steel Stainless Steel Aluminum 50700 IPM(1.317.8 m/min)

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

181 lb(82 kg)

.023 .045 in.(0.8 1.1 mm)

.030 .045 in.(0.8 1.1 mm)

.035 .047 in.(0.9 1.2 mm)

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

3-2. Duty Cycle And Overheating

6 Minutes Welding 4 Minutes Resting

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

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

NOTICE Exceeding duty cyclecan damage unit and void warranty.

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutes

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

sduty1 5/95 / 217 442-A

4 Minutes Welding 6 Minutes Resting

10 15 20 25 30 40 50 60 70 80 90 100100

150

200225250

300

400

500

% DUTY CYCLE

WE

LD

ING

AM

PE

RE

S

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OM-1327 Page 12

3-3. Volt-Ampere Curve

217 443-A

1 Normal Volt-Ampere Curves

The volt-ampere curves show thenormal minimum and maximumvoltage and amperage outputcapabilities of the welding powersource. Curves of other settings fallbetween the curves shown.

MAXVOLTSMINVOLTS

0 50 100 150 200 250 300 3500

10

20

30

40

50

60

70

80

90

VO

LTA

GE

AMPERAGE

3-4. Connecting To Weld Output Terminals

803 778-A

! Turn off power before connecting toweld output terminals.

! Failure to properly connect weldcables may cause excessive heatand start a fire, or damage your ma-chine.

1 Weld Output Terminal2 Supplied Weld Output Terminal Nut3 Weld Cable Terminal4 Copper BarRemove supplied nut from weld output ter-minal. Slide weld cable terminal onto weld

output terminal and secure with nut so thatweld cable terminal is tight against copperbar. Do not place anything between weldcable terminal and copper bar. Makesure that the surfaces of the weld cableterminal and copper bar are clean.

Tools Needed:

3/4 in. (19 mm)

4

2

3

Do not placeanything between

Correct Installation Incorrect Installation

1

weld cable terminaland copper bar.

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

OM-1327 Page 13

3-5. Installing Work Clamp

1 Work Cable

2 Boot

Route cable through front panelopening. Slide boot onto workcable.

3 Negative () Output Terminal

Connect cable to terminal andcover connection with boot.

Close door.

803 540-C

Tools Needed:

3/4 in.

3

2

1

3-6. Installing Welding Gun/Cable Holder

1 Welding Gun/Cable Holder

2 Wrapper

3 Screw Locations

Remove screws from side panel.Place holder against side panel andalign screw holes. Secure holder toside panel with the previouslyremoved screws.

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

1

2

3

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OM-1327 Page 14

3-7. Installing Welding Gun

1 Drive Assembly

2 Gun Securing Knob

3 Gun End

Loosen securing knob. Insert gunend through opening until it bottomsagainst drive assembly (make suregun end does not touch drive rolls).Tighten knob.

4 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

Close door.

Ref. 803 541-C

1

4

32

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OM-1327 Page 15

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

803 568-D

1 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

2 Weld Cable

3 Shielding Gas Hose

Route weld cable and gas hosethrough opening in front panel.

4 Positive Weld Output Terminal

Connect weld cable to weld outputterminal.

5 Regulator/Flowmeter

Route shielding gas hose throughwire drive compartment, outopening in rear panel, and up toregulator/flowmeter. Connect gashose to regulator/flowmeter.

Tools Needed:

3/4, 5/8 in.

1

23

4

2

5

3

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

OM-1327 Page 16

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

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

XR Edge guns prior to serial no.LE079101 require an adaptercord (part no. 195 498).

1 Gun End

2 Gun Liner

3 Wire Outlet Guide

Trim excess liner from end of gunso no more than 3/32 in. (2.4 mm) ofliner extends past wire outlet guide.

4 Gun Securing Knob

Loosen securing knob. Insert gunend through opening until it bottomsagainst drive assembly (make suregun end does not touch drive rolls).Tighten knob.

Be sure to change drive rolls to theproper size and type.

5 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

32

3/32 in.(2.4 mm)

Be sure to trim liner to proper extension.

1

5

4

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OM-1327 Page 17

3-10. Setting Gun Polarity For Wire Type

1 Polarity Changeover Information

Always read and follow manufacturesrecommended polarity.

1

3/4, 11/16 in.

Ref. 803 541-A

Changing Polarity

Wire DriveAssembly Lead

Work Clamp Lead

PositiveTerminal

Shown as shipped Electrode Positive (DCEP): Forsolid steel, stainless steel, aluminum, or flux core withgas wires (GMAW).

NegativeTerminal

Electrode Negative (DCEN): Reverse lead connectionsat terminals from that shown above for gasless flux corewires (FCAW). Drive assembly becomes negative.

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OM-1327 Page 18

3-11. Installing Gas Supply

803 542-C

Tools Needed:

1-1/8, 5/8 in.

1

2

34

5

7

Rear Panel

6

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 ofvalve, and open valve slightly. Gasflow blows 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 onrear of welding power source.

7 Flow Adjust

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

8 CO2 Adapter (CustomerSupplied)

9 O-Ring (Customer Supplied)

Install adapter with O-ring betweenregulator/flowmeter and CO2cylinder.

1

2

3

8 9

Argon Gas Or Mixed Gas

CO2 Gas

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OM-1327 Page 19

3-12. Installing Wire Spool and Adjusting Hub Tension

Ref. 805 023-A

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

15/16 in.

Use compression spring with8 in (200 mm) spools.

Tools Needed:

3-13. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. Theserecommendations 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 Amperes1

Time-Delay Fuses 2 80 70 35 25 40 35 15 10

Normal Operating Fuses 3 100 90 40 35 50 45 20 15

Min Input Conductor Size In AWG 4 6 8 10 12 10 10 14 14

Max Recommended Input Conductor Length In Feet (Meters)101(31)

86(26)

229(70)

217(66)

86(26)

114(35)

178(54)

227(85)

Min Grounding Conductor Size In AWG 4 8 8 10 12 10 10 14 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.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 voltageavailable at site to be sure it matches the voltage specified on the rating label.

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

OM-1327 Page 20

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

803 539-C / 804 042-A

! Turn Off welding powersource, disconnect inputpower, and check voltage oninput capacitors accordingto Section 6-3 beforeproceeding.

Check input voltage availableat site.

Incorrect linking can damageunit and void the warranty.

1 Voltage Selection ViewWindow

Check voltage selected in unit.Changing selection is only neces-sary if selected value does notmatch available input voltage.

2 Relinking Board PC6

3 Mounting Screws

4 Receptacle RC23(Connection For 230 VACInput Power)

5 Receptacle RC46(Connection For 460 VACInput Power)

Move relinking board as neededand connect plug PLG32 (in unit) toRC23 or RC46 according to inputpower voltage.

Tools Needed:

5/16 in.

Be sure to reinstall all four screwssecuring relinking board in place.

2

3

4

3

5

1

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OM-1327 Page 21

3-15. 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.

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

Ref. 803 543-E / 803 766-A

! Installation must meet all National andLocal Codes - have only qualifiedpersons make this installation.

! Disconnect and lockout/tagout inputpower before connecting inputconductors from unit.

! Always connect green or green/yellowconductor to supply grounding terminalfirst, and never to a line terminal.

! Warning: This unit is either a200/230/460 ac input voltage model or460/575 ac input voltage model. Seerating label on unit and check voltage

available at site to be sure it matchesthe voltage specified on the ratinglabel.

1 Input Power Cord Strain Relief

2 Input Power Cord

3 Disconnect Device (switch shown inthe OFF position)

4 Green Or Green/Yellow GroundingConductor

5 Disconnect Device Grounding Terminal

6 Input Conductors (L1, L2 And L3)

7 Disconnect Device Line Terminals

Connect green or green/yellow grounding

conductor to disconnect device groundingterminal first.

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

8 Over-Current Protection

Select type and size of over-currentprotection using Section 3-13 (fuseddisconnect switch shown).

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

Tools Needed:

21

Rear Panel

18 in. (457 mm) for airflow

! Do not move or operateunit where it could tip.

= GND/PE Earth Ground

3

3

4

5

7

6

8

L1L2L3

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OM-1327 Page 22

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

Ref. 803 543-E / 803 766-A

Tools Needed:

3

2

7

6

4

! Installation must meet all National andLocal Codes - have only qualifiedpersons make this installation.

! Disconnect and lockout/tagout inputpower before connecting inputconductors form unit.

! Always connect green or green/yellowconductor to supply grounding terminalfirst, and never to a line terminal.

! Warning: This unit is either a200/230/460 ac input voltage model or460/575 ac input voltage model. Seerating label on unit and check voltageavailable at site to be sure it matchesthe voltage specified on the ratinglabel.

Three Conductor Power Cord Preparation

1 Input Power Cord Strain Relief

2 Input Power Cord

3 Black And White Input Conductors (L1And L2)

4 Red Input Conductor5 Green Or Green/Yellow Grounding

Conductor

6 Insulation Sleeving

7 Electrical Tape

Insulate and isolate red conductor as shown.

Disconnect Device Input PowerConnections

8 Disconnect Device (switch shown inthe OFF position)

9 Disconnect Device Grounding Terminal

10 Disconnect Device Line Terminals

Connect green or green/yellow groundingconductor (see Item 5) to disconnect devicegrounding terminal first.

Connect input conductors L1 and L2 todisconnect device line terminals.

11 Over-Current Protection

Select type and size of over-current protec-tion using Section 3-13 (fused disconnectswitch shown).

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

5

Rear Panel

18 in. (457 mm) for airflow

! Do not move or operateunit where it could tip.

=GND/PE Earth Ground

8

1

5

3

9

10

11

L1L2

21

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OM-1327 Page 23

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 Guide7 Pressure Adjustment Knob

8 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

6 in.(150 mm)

Hold wire tightly to keepit from unraveling.

WOOD

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

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

Remove gun nozzle and contact tip. Turn On.

Press gun trigger until wire comes out of gun. Reinstall

contact tip and nozzle

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

Tighten

1234

Use pressure indicator scale to seta desired drive roll pressure.

PressureIndicator

Scale

Tighten

1234

7

83 5 621 4

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OM-1327 Page 24

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 Guide7 Pressure Adjustment Knob

8 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

6 in.(150 mm)

Hold wire tightly to keepit from unraveling.

Open pressure assembly.Pull and hold wire; cut off end.

Push wire thru guides into gun;continue to hold wire.

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

See Section 3-20 for threadingwelding wire through XR guns.

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

Tighten

1234

Use pressure indicator scale toset front drive roll pressure to 1and rear drive roll pressure toless than 1.

PressureIndicator

Scale

218243-A

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

IMPORTANT!For AluminumPush-Pull welding.

12

34

218244-A

7

83 5 621 4

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OM-1327 Page 25

3-20. Threading Welding Wire Through XR Guns

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

Tools Needed:

! Welding wire is electrically livewhen gun trigger is used to jogwire.

Refer to Section 3-19 for instructionson feeding wire through welding pow-er source.

1 Pressure Roll Assembly

Lay gun cable out straight.

Open top cover, and open pressure roll as-sembly. If not already done, remove gunbarrel assembly.

Press gun trigger until about 4 in. (102 mm)of wire is sticking out front of gun. Insertwire into barrel liner and tighten barrel as-sembly. Install correct size contact tubeand install collet nut.

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

XR Edge gun drive roll pressureshould be set at minimum.

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.

NonconductiveSurface

For XR-A Edge Gun:

For XR-A Pistol Gun:

1 Pressure Roll Assembly

2 Drive Roll

3 Thumbscrew

Lay gun cable out straight. Open topcover, and lift pressure arm and openpressure roll assembly. If not alreadydone, remove gun barrel assembly.

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

4 Pressure Adjustment Knob

See final pressure adjustment at bottom ofpage.

1

2

Turn OnWelding Power

Source.

Turn OnWelding Power

Source.

1

3

Remove barrel assembly beforethreading wire through gun.

Remove barrel assemblybefore threading wire

through gun.

For XR-A Pistol Gun:

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OM-1327 Page 26

SECTION 4 OPERATION4-1. Controls

1 Pulse Indicator Light

Pulse only lights if unit has the pulseMIG module and is programmed forpulse MIG.

2 MIG Indicator Lights

Pulse (1) and MIG (2) illuminate to Indicateweld mode of unit.

3 Process Light

PROCESS illuminates when unit is inProcess select menu.

4 Wire Light

WIRE illuminates when unit is in Pulse MIGprogram select menu.

5 Timers Light

TIMERS illuminates when unit is in Timersmenu.

6 Setup Button

Use button to access Timers, Process andWire menus.

7 Arc Control Button

Use button to select either inductancecontrol in MIG welding mode or Sharp Arcin Pulse MIG welding mode.

8 Left Knob

Use knob to adjust volts in MIG weldingmode or change parameter values inSetup.

9 Right Knob

Use knob to adjust wire speed in MIGwelding mode or change parameter valuesin Setup.

10 Left Display

11 Right Display

12 Weld Functions/Setup IndicatorLights

VOLTS illuminates in MIG welding modeindicating volts in left display can beadjusted. Also, VOLTS lights to indicate leftdisplay is showing actual voltage duringwelding and for 5 seconds after the arc isextinguished.ARC LENGTH illuminates in Pulse MIGwelding mode indicating Arc Length can beadjusted.SETUP illuminates when a parameter onthe corresponding display above the lightcan be adjusted.WIRE SPEED illuminates in either PulseMIG or MIG welding mode indicating wirespeed can be adjusted.AMPS illuminates indicating welding ampsappears in the display, instead of wirespeed, during welding and for 5 secondsafter the arc is extinguished.

1

11

Ref. 213 935-A98

6

5

4

3

10

12

7

2

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 adjustwelding voltage within a range of 10-32 volts, and right knob is used to adjust wire feed speed within a range of 25-700IPM. Refer to weld chart in front compartment for proper parameter settings according to wire type, shielding gas, andmaterial 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 weldpower. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow

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

OM-1327 Page 27

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 beforeshutting 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 beshown on the displays for 5 seconds. The VOLTS and AMPS indicator lights will illuminate under the displays and eachvalue will appear in the corresponding display.

If a programmed value requires adjustment after the arc is extinguished and during the 5 seconds display of actualvalues, turning either knob will cause actual values in the displays to be replaced by programmed values foradjustment 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 (seeSection 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 toanother, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger ispressed, 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 wirefeed speed. Arc Length adjustment is used to adjust actual arc length which automatically adjusts the voltage. Seeweld 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 thetrigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored dataand both displays will show the last programmed values for that particular gun. For a spool gun, the wire speed is takenfrom the position of the gun potentiometer. This wire speed value is automatically adjusted if the potentiometer ismoved since the last time the gun was active. If the unit is powered down and back on again, the gun last used willbecome 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 shutsoff after 1 second to prevent wire burnback in the contact tip.

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OM-1327 Page 28

4-9. Weld Parameters For MIG Mode

Mat

eria

lS

teel

Ste

el

Alu

min

um

Sta

inle

ss S

teel

Gas

100%

Co

2

75%

Arg

on25

% C

o2

90%

Hel

ium

7.5%

Arg

on2.

5% C

o2

100%

Arg

on

Wir

e1/

23/

81/

43/

16

1/8

14g

a16

ga

18g

a20

ga

22g

a

3/64

535

624

.0/5

3523

.5/5

0022

.5/4

6521

.0/3

7519

.0/3

40

.035

404

3

3/64

404

3

.035

535

6

23

.5/7

0018

.2/3

00

24.0

/475

23.5

/435

23.0

/375

21.5

/305

19.5

/250

Indu

ctan

ce =

20

40

23.5

/220

Vol

ts/W

irefe

edR

efer

ence

Indu

ctan

ce =

20

40

Indu

ctan

ce =

60

80

Indu

ctan

ce =

30

.035

.035

.045

23

.0/3

2521

.5/2

8020

.5/2

4020

.0/2

1019

.0/1

7518

.5/1

6018

.0/1

1517

.0/9

016

.5/8

0

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

US

ES

PR

AY19

.0/2

2018

.0/2

0017

.5/1

7016

.2/1

5016

.0/1

3015

.5/1

00

24.0

/400

23.0

/300

20.5

/250

20.0

/235

19.5

/175

19.0

/160

.045

.045

.035

23

.0/2

2021

.5/2

0020

.5/1

7520

.0/1

5019

.0/1

1018

.5/1

05

25

.0/4

5022

.5/4

4021

.5/3

7521

.0/3

2520

.0/2

7518

.0/2

3518

.5/2

0017

.5/1

50

29.3

/530

(12.

7mm

)(9

.5m

m)

(6.4

mm

)(4

.8m

m)

(3.2

mm

)(2

.0m

m)

(1.6

mm

)(1

.2m

m)

(0.9

mm

)(0

.8m

m)

No

te: A

ll ch

art

par

amet

ers

refe

ren

ce s

etti

ng

s fo

r H

ori

zon

tal T

fill

et w

eld

s. S

etti

ng

s m

ay n

eed

to b

e m

od

ifie

d f

or

oth

er t

ypes

of

wel

din

g jo

ints

or

wel

din

g p

osi

tio

ns.

MIG

CH

AR

TM

IG C

HA

RT

Met

al C

ore

Indu

ctan

ce =

30

.045

26.0

/400

24.5

/350

23.5

/300

90%

Arg

on10

% C

o2

27

.0/4

2529

.0/4

75

19.2

/380

19.0

/450

21.5

/450

21.0

/520

23.0

/530

23.0

/660

23.5

/800

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

OM-1327 Page 29

4-10. Weld Parameters For Pulse Mode

.04

5

.04

5

3/6

4

40

43

3/6

4

53

56

.03

5

53

56

WELDCHARTS

3/16

(4.8mm)

1/8

(3.2mm)

14ga

(2.0mm)

16ga

(1.6mm)

18ga

(1.2mm)

19ga

(1.0mm)

22ga

(0.8mm)

Gas

Wire

Material

90

%

Arg

on

10

%

Co

2

.03

5S

teel

Ar/

He/C

O2

Tri

-M

ix

.03

5S

tain

less

Ste

el

.03

5

40

43

1/2

(12.7mm)

50

0

45

0

45

0

65

0

60

0

75

0

3/8

(9.5mm)

45

0

35

0

39

0

55

0

55

0

50

0

65

0

1/4

30

0

20

0

32

5

40

5

72

0

40

0

40

0

55

0

20

0

15

0

26

0

35

0

64

0

30

0

30

0

45

0

15

0

12

5

20

0

29

0

45

0

25

0

20

0

31

0

12

5

10

0

14