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7/25/2019 Millermatic 252 Operators Manual

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Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Sourceand Wire Feeder

OM-230 693J 201004

Millermatic 252

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


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Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank youand congratulationson choosing Miller. Now you can get

the job done and get it done right. We know you dont have time to do

it 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 superior

quality. Like you, his customers couldnt afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. Theyre just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

theres a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

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

From Miller to You

Mil_Thank 200909


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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE 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 DEFINITIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Symbols And Definitions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Welding Power Source Duty Cycle And Overheating 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Volt-Ampere Curves 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Connecting To Weld Output Terminals 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Installing Work Cable And Clamp 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Connecting Spoolmatic) 15A Or 30A Gun 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8. Setting Gun Polarity For Wire Type 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Installing Gas Supply 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. Installing Wire Spool And Adjusting Hub Tension 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11. Positioning Jumper Links 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. Electrical Service Guide 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Serial Number And Rating Label Location 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14. Selecting A Location And Connecting Input Power 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15. Threading Welding Wire 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16. Weld Parameters 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Voltmeter And Wire Feed Speed Meter Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Jog Mode 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Timers 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Set Up Push Motor Torque (SUP) Or Reset (rES) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE &TROUBLESHOOTING 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Routine Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Unit Overload 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Changing Drive Roll and Wire Inlet Guide 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Aligning Drive Rolls and Wire Guide 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Troubleshooting 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TABLE OF CONTENTS

SECTION 8 MIG WELDING (GMAW) GUIDELINES 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1. Typical MIG Process Connections 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2. Typical MIG Process Control Settings 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Holding And Positioning Welding Gun 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4. Conditions That Affect Weld Bead Shape 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5. Gun Movement During Welding 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6. Poor Weld Bead Characteristics 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7. Good Weld Bead Characteristics 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8. Troubleshooting Excessive Spatter 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9. Troubleshooting Porosity 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10. Troubleshooting Excessive Penetration 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11. Troubleshooting Lack Of Penetration 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12. Troubleshooting Incomplete Fusion 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13. Troubleshooting Burn-Through 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14. Troubleshooting Waviness Of Bead 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15. Troubleshooting Distortion 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-16. Common MIG Shielding Gases 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17. Troubleshooting Guide For Semiautomatic Welding Equipment 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 PARTS LIST 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY


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OM-230 693 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 symbols

or 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.

NOTICEIndicates 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 are

electrically 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 metal

and 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 directly

with 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 any

single 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.


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OM-230 693 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) rays

that 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 can

damage hearing. Wear approved ear protection if noise level is

high.

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.


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OM-230 693 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 is

properly 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 Owners

Manuals, 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, keep

spark 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 grounded

according to this manual. If interference still occurs, the user must take extra measures

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


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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, birth

defects, 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,Chanti lly, 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

Electr ic current flowing through any conductor causes localized electricand magnetic fields (EMF). Welding current creates an EMF field

around 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.


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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.

NOTEIndique 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. En

prsence 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 peut

provoquer 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 et

sans 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. Dverrouillerlalimentationselon 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 directement

avec 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 machines

en 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 correctement

en 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.


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OM-230 693 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 dtravailler 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 soudaggnre des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brlure

dans les yeux et sur la peau. Des tincelles sont projetes pendant lsoudage.

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 sparation

peut dclencher un incendie de lautre ct. Ne pas effectuer le soudage sur des conteneurs ferms tels que

des 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 particulesmtall iques volantes. Pendant la priode de refroidissement dessoudures, elles risquent de projeter du laitier.

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


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OM-230 693 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 lorsque

la 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 que

lalimentationest 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 lmeuleuse dote de protecteurs. Cett

manuvre est excuter dans un endroit srlorsque lon porte lquipement homologu dprotection 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.


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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, recouvrements

ou dispositifs de protection uniquement par du personnel qua-lifi. Remettre les portes, panneaux, recouvrements ou dispositifs de

protection 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 lectricien

qualifi 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.


13/52

OM-230 693 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, site

Internet : www.nfpa.org et www.sparky.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de Compressed Gas Association, 4221 Walney Road, 5th Floor, 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 Printing

Office, 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 soudage

cre 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.


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OM-230 693 Page 10


15/52

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

OM-230 693 Page 11

SECTION 3 DEFINITIONS

3-1. Symbols And Definitions

Wire Feed Output X Duty Cycle Do Not SwitchWhile WeldingV Volts Increase On Off

Gas Metal ArcWelding (GMAW)

Gun

Wire Feed SpoolGun Gas Input Gas Output

Voltage Input Press To Reset U0 Rated No-LoadVoltage (Average)

SECTION 4 INSTALLATION

4-1. Specifications

Rated Output Max. Open CircuitVoltage

Amps Input at Rated Output (60% Duty Cycle), 60 Hz, Single-Phase200 (208) V 230 V 460 V 575 V KVA KW

250 A at 28 VDC,40% Duty Cycle

200 A at 28 VDC,60% Duty Cycle

38 482.3*

462*

231*

180.8*

9.80.46*

7.50.13*

Wire Type and Diameter Wire Feed Speed Dimensions Net Weight Without Gun

Solid Steel Stainless Steel Flux Cored 50700 IPM(1.317.8 m/min)

H: 30 in. (762 mm)W: 19 in. (483 mm)D: 40 in. (1016 mm)

205 lb(93 kg)

.023 .045 in.(0.6 1.2 mm)

.023 .045 in.(0.6 1.2 mm)

.030 .045 in.(0.8 1.2 mm)

* While idling

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


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OM-230 693 Page 12

4-2. Welding Power Source Duty Cycle And Overheating

4 Minutes Welding 6 Minutes Resting6 Minutes Welding 4 Minutes Resting

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

If unit overheats, Thermistor (RT1)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orvoltage, or duty cycle beforewelding.

NOTICE

Exceeding duty cyclecan damage unit and void warranty.

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutes

duty1 4/95 150 215-A

40% Duty Cycle At 250 Amperes60% Duty Cycle At 200 Amperes

10 20 30 40 50 60 70 80 90 10050

100

150

200

250

300350400450500

% DUTY CYCLE

WELDAM

PERES

4-3. Volt-Ampere Curves

ssb1.1 10/91 239 342

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.

1

0

5

10

15

20

25

30

35

40

0 50 100 150 200 250 300 350

Volt minVolt max

Amperes

Volts


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OM-230 693 Page 13

4-4. 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 Terminal

4 Copper BarRemove supplied nut from weld outputterminal. Slide weld cable terminal onto

weld output terminal and secure with nut sothat weld cable terminal is tight againstcopper bar. Do not place anything

between weld cable terminal and copperbar. Make sure that the surfaces of theweld cable terminal and copper bar areclean.

Tools Needed:

3/4 in. (19 mm)

4

2

3

Do not placeanything between

Correct Installation Incorrect Installation

1

weld cable terminal

and copper bar.

4-5. Installing Work Cable And Clamp

Tools Needed:

3/4 in.

1 Work Cable2 Boot

Route cable through front panelopening. Slide boot onto workcable.

3 Negative () Output Terminal

Connect cable to terminal andcover connection with boot.

Close door.

2

3

1

804 909-A


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OM-230 693 Page 14

4-6. Connecting Spoolmatic15A Or 30A Gun

804 910-A

1 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

2 Weld Cable3 Shielding Gas Hose

Route weld cable through openingin front panel.

Route gas hose along side panel.

4 Positive Weld Output TerminalConnect weld cable to weld outputterminal.

5 Regulator/Flowmeter

Route shielding gas hose up toregulator/flowmeter. Connect gashose to fitting on regulator/flowmeter.

Two welding guns may beconnected to the weldingpower source at the same time,but only one welding gun maybe in use at any one time. If thetriggers of both welding gunsare pulled at the same time, theweld output and wirefeed motor

are disabled.

Tools Needed:

3/4, 5/8 in.

5

3

4

1

3

2


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OM-230 693 Page 15

4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python

Ref. 804 910-A / 804 936-A

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

1 Gun End2 Gun Liner3 Wire Outlet Guide

Trim excess liner from end of gunso no more than 3/32 in. (2.4 mm) of

liner 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.

If Aluma-Pro push/pull gun hasa listed SUP value, set the

power source to match theSUP value (see Section5-5).

32

3/32 in.(2.4 mm)

Be sure to trim liner to proper extension.

5

4

1


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OM-230 693 Page 16

4-8. Setting Gun Polarity For Wire Type

1 Polarity Changeover LabelInformation

Always read and follow manufacturesrecommended polarity.

1

3/4, 11/16 in.

Ref. 190 821-A

Changing Polarity

Wire DriveAssembly Lead

Work Clamp Lead

Positive Terminal

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

Negative Terminal

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

4-9. Installing Gas Supply

Ref. 804 654-A / Ref. 804 912-A

Tools Needed:

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 customer supplied gashose between regulator/flowmetergas hose 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 (Customer

Supplied)9 O-Ring (Customer Supplied)

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

1-1/8, 5/8 in.

1

2

37

Rear Panel

6

4

5

1

2

3

8 9

Argon Gas Or Mixed Gas

CO2Gas


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OM-230 693 Page 17

4-10. Installing Wire Spool And Adjusting Hub Tension

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

15/16 in.

Use compression springwith 8 in. (200 mm) spools.

Tools Needed:

072573-B / 802 922

Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wirespool, follow the procedure asshown in the illustration.

Remove thesecomponentsfrom spindle.

Spindle

SpindleInstall thesecomponentsonto spindle.

Order extra springPart No. 186 437

4-11. Positioning Jumper Links

Tools Needed:

3/8 in.

Check input voltage available at

site.1 Jumper Links Access Door

Open door.

2 Jumper Link Label

Check label only one is on unit.

3 Input Voltage Jumper Links

Move jumper links to match inputvoltage.

Close and secure access door.

153 980-D / 144 916-E / 804 911-A

2

200 VOLTS 230 VOLTS

153 980-D

230 VOLTS 460 VOLTS 575 VOLTS

144 916-E3

1


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OM-230 693 Page 18

4-12. Electrical Service Guide

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 Hz Single Phase

Input Voltage (V) 200 230 400 460 575

Input Amperes (A) At Rated Output 48 46 24 23 18

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses2

60 50 30 25 20Normal Operating Fuses 3 70 60 35 30 25

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

Max Recommended Input Conductor Length In Feet (Meters)96

(29)127(39)

156(47)

206(63)

209(64)

Min Grounding Conductor Size In AWG 4 8 10 12 12 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.


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OM-230 693 Page 19

4-13. 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.

4-14. Selecting A Location And Connecting Input Power

804 912-A

L1L2

230 VAC, 1

18 in. (457 mm) ofspace for airflow

! Do not move or operateunit where it could tip.

2

! Installation must meet all Nationaland Local Codes have only qualifiedpersons make this installation.

! Disconnect and lockout/tagout inputpower before connecting input con-ductors from unit.

! Always connect green or green/yel-low conductor to supply groundingterminal first, and never to a line ter-minal.

! Special installation may be requiredwhere gasoline or volatile liquids arepresent see NEC Article 511 or CECSection 20.

1 Plug (NEMA Type 6-50P)

2 Receptacle[NEMA Type 6-50R (CustomerSupplied)]

3 Input Power Cord.

Connect directly to line disconnect device ifhard wiring is required.

4 Black And White Input Conductor (L1And L2)

5 Green Or Green/Yellow GroundingConductor

6 Disconnect Device (switch shown inthe OFF position)

7 Disconnect Device Grounding Terminal

8 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.

9 Over-Current Protection

Select type and size of over-currentprotection using Section 4-12 (fused

disconnect switch shown).Connect plug to receptacle if hard wiringmethod is not used.

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

13

1

=GND/PE Earth Ground

6

L1L2

54

7

8

9


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OM-230 693 Page 20

4-15. Threading Welding Wire

1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Outlet Wire Guide7 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

6 in.(150 mm)

Hold wire tightly to keep itfrom 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 pressureassembly, and let go of wire.

Remove gun nozzle and contact tip. Turn On.

Press gun trigger until wirecomes out of gun. Reinstall

contact tip and nozzle

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

Cut off wire. Closeand latch door.

Ref. 804 913-A

Tighten

1234

Use pressure indicator

scale to set a desireddrive roll pressure.

PressureIndicator

Scale

Tighten

1234

4

7

5 6

213


25/52


OM-230 693 Page 21

Notes


26/52


OM-230 693 Page 22

4-16. Weld Parameters


27/52


OM-230 693 Page 23

226 650-B


28/52


OM-230 693 Page 24

SECTION 5 OPERATION5-1. Controls

226 647-B

1 Voltage Control

Turn control clockwise to increasevoltage.

2 Wire Speed Control

Turn control clockwise to increase wire

feed speed.3 Voltmeter4 Wire Feed Speed Meter

2

3

This unit has three automatic timers included in its operation to help save contacttips, gas, and wire:

Tip Saver Weld output shuts off if tip is shorted to work surface.

Safety shut-off Weld output will shut off if no arc is detected within 3 seconds aftergun trigger is depressed.

Jog mode When loading a new roll of wire or if the gun trigger is accidentallypressed, gas will shut off after 1 minute and wire will shut off after 2 minutes savingwire and gas.

1

4


29/52


OM-230 693 Page 25

JOG Mode

If the trigger on either gun is held for morethan 3 seconds without striking an arc, theunit will automatically shut off weld power(and shielding gas output on MIG gunonly), but will feed wire continuously at thepreset wire feed speed (which may befaster or slower than Runin Speed) untiltrigger is released.

Runin Wire Feed Speed Settings

Runin settings for the MIG and SpoolGuns are independently set and stored inunit memory. The settings are in percent ofthe welding wire feed speed preset. Bothsettings are adjustable from 25 to 150percent.

MIG Gun Runin is factory set at 100%which is recommended for most wire sizesand types.Spool Gun Runin is factory set at 50%which is recommended for .030 & .035wire. A Runin setting of 25% isrecommended for .047 wire.To check Runinsettings, start with thepower switch OFF. Press and hold the MIGor Spool Gun Trigger while turning thepower switch ON. The unit will power upwith both the displays reading888, thenthe voltage display will read runand thewire feed display will read the presetRunin percentage from memory for thegun selected. To return to the weld modewithout making a change, simply releasetrigger and pull the trigger againmomentarily (one second).

To change Runinsettings, start with thepower switch OFF. Press and hold the MIGor Spool Gun Trigger while turning thepower switch ON. The unit will power upwith both the displays reading888, thenthe voltage display will read runand thewire feed display will read the presetRunin percentage from memory for thegun selected. To change the Runin value,release the trigger and turn the wire feedcontrol knob (or the wire feed adjustmentknob located on the bottom handle of thespool gun) to the desired setting for theselected gun. To return to weld mode afterthe Runin speed change, pull the triggermomentarily (one second).


30/52


OM-230 693 Page 26

5-2. Voltmeter And Wire Feed Speed Meter Operation

1 Voltmeter

2 Wire Feed Speed Meter

Power Up Status

Both meters display888at unit power up.After 0.5 seconds, preset values appear onboth meters. The settings for the last activegun used will be the default at initial powerup of the unit. If the power is reset to quickly,characters other than 888 may appear. Toreset, turn power off for at least 3 seconds,then turn power back on.

Welding Status

When either a MIG gun or spool gun triggeris pressed and a welding arc is established,the voltmeter displays actual weld voltage.

When the gun trigger is released andwelding arc extinguished, the voltmeterdisplays the last actual voltage for 5seconds and then returns to preset voltage.If welding resumes before unit displayspreset voltage, actual welding voltage willappear on the voltmeter.

The wire feed speed meter always displayspreset wire feed speed (IPM).

Gun Selection

The wire feed speed meter will displaypreset wire feed speed (IPM) for theappropriate gun selection either MIG,

Spool or Push/Pull gun. To preset desiredwire feed speed, connect desired gun,press gun trigger for one second, andrelease trigger. The meter preset will beretained by the meter board until a differentgun is connected and preset is performedor the unit is turned off and back on. Thesettings for the last active gun used will bethe default at initial power up of the unit.

1 2

5-3. Jog Mode

If the trigger on either gun is held for more than 3 seconds without striking an arc, the unit will automatically shut offweld power (and shielding gas output on MIG or push/pull gun), but will feed wire continuously at the preset wire feedspeed (which may be faster or slower than Runin Speed) until trigger is released. Jog wire feed speed is the same asweld wire feed speed, so any time jog speed is changed, be sure to change back to weld wire feed speed beforewelding. Jog wire feed speed for the spool gun and push/pull gun is limited to 300 ipm (7.6 m/min).


31/52


OM-230 693 Page 27

5-4. Timers

1 Voltage Control

2 Wire Speed Control

3 Voltmeter

4 Wire Feed Speed Meter

To enter theTIMERSmenu press and holdthe gun trigger while turning on the powerswitch until the left meter displays (run),then release trigger.

Once in the TIMERSmenu, rotate the leftknob clockwise (CW) to find the particularitem, and rotate the right knob to changethe setting.

The following items can be adjusted byrotating the left knob clockwise (CW):

Run-in speed(run) The speed of the wireprior to the welding arc being struck. Therange is from 25 to 150% of wire feedspeed(WFS).Preflow(PrE) The amount of time thatthe shielding gas will flow after the triggeris depressed and before the welding arcwill be allowed to be active. The range isfrom 0.0 to 5.0 seconds.Postflow(POS) The amount of time thatthe shielding gas will flow after the arc hasbeen shut off. The range is from 0.0 to 10.0seconds.Burnback(Bur) The amount of time thatthe welding wire remains electrically ener-

gized after the wire feeding has stopped.The range is from 0.01 to 0.25 seconds.

Spot Timer(SPO) The amount of timethat the arc will be active before it shuts offautomatically. The range is from 0 to 120seconds. Spot timer is reset upon releaseof welding gun trigger.

Stitch Timer (dLY) Used inconjunction with the Spot timer and whilethe trigger is continuously depressed.Controls the amount of time that the arc willbe inactive after the Spot timer times out.The range is from 0 to 120 seconds.

To save settings and exit the TIMERSmenu, depress the gun trigger.

2

3

1

4


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OM-230 693 Page 28

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

5-5. Set Up Push Motor Torque (SUP) Or Reset (rES)

1 Voltage Control2 Wire Speed Control3 Voltmeter4 Wire Feed Speed MeterDepress the gun trigger while turning onthe power switch until the left meterdisplays (run).Rotate the left knob counterclockwise(CCW) to find the particular item, and rotatethe right knob to change the setting.

The following items can be adjusted byrotating the left knob counterclockwise(CCW):Set up Push Motor Torque(SUP) Thisfeature is only active when a push/pull gunis connected to the welding power source.The (SUP) setting will adjust theover-torque limit of the push motor insidethe welding power source. The range is0-250 and the default value is 130.Increasing this setting will increase the

over-torque limit and speed up the remotewire feed speed motor.

If Aluma-Pro push/pull gun has a listedSUP value, set the power source tomatch the SUP value.

To save settings and exit the (SUP) menu,depress the gun trigger.Reset (rES) Rotate the right knob toselect ON. Press and release gun trigger toreset system to factory default values.

2

3

1

4


33/52


OM-230 693 Page 29

SECTION 6 MAINTENANCE &TROUBLESHOOTING

6-1. Routine Maintenance

! Disconnect powerbefore 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 Apply Light Coat Of OilOr Grease To Drive MotorShaft

Clean Drive Rolls

6-2. Unit Overload

Thermistor RT1 in SCR1 protects the unit from damage due to overheating. If HL.P 002 is displayed on the meters,wait for unit to cool allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contactFactory Authorized Service Agent.

6-3. Changing Drive Roll and Wire Inlet Guide

1 Securing Screw2 Inlet Wire Guide

Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw.

3 Drive Roll

The drive roll consists of twodifferent sized grooves. Thestamped markings on the endsurface of the drive roll refers to thegroove on the opposite side of thedrive roll. The groove closest to themotor shaft is the proper groove tothread (see Section 4-15).

4 Drive Roll Securing Nut

Turn nut one click to secure driveroll.

Tools Needed:

7/16 in.

1

2

3

4

Ref. 804 914-A


34/52


OM-230 693 Page 30

6-4. Aligning Drive Rolls and Wire Guide

! Turn Off power.View is from top of drive rollslooking down with pressureassembly open.

1 Drive Roll Securing Nut2 Drive Roll3 Wire Guide4 Welding Wire

5 Drive GearInsert screwdriver, and turn screwin or out until drive roll groove linesup with wire guide.

Close pressure roll assembly.

Ref. 800 412-A

Correct Incorrect43

21

5

Tools Needed:


35/52


OM-230 693 Page 31

6-5. Troubleshooting

Trouble Remedy

No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-14).

Replace building line fuse or reset circuit breaker if open (see Section 4-14).

Secure gun trigger connections (see welding gun Owners Manual).

HL.P 001 appears on meters. Turn power switch off and back on, if HL.P 001 appears on meters again,have Factory Authorized Service Agent check unit.

HL.P 002 appears on meters. Thermistor RT1 is detecting an overheating condition. Wait for unit to coolallowing the fan to run. After unit is cool, if HL.P 002 message remains, have Factory Authorized ServiceAgent check for an open Thermistor RT1 (see Section 6-2).

HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causingshort circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check forshorted trigger leads.

Have Factory Authorized Service Agent check Power switch.

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

No Weld Output; wire feeds. Connect work clamp to get good metal to metal contact.

Replace contact tip (see welding gun Owners Manual.

HL.P 003 appears on meters, have Factory Authorized Service Agent check main control board and mainrectifier.

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 4-14).

Check input voltage jumper links and correct position if necessary (see Section 4-11).

Have Factory Authorized Service Agent check main control board.

Fan motor does not run. Have Factory Authorized Service Agent check fan-on-demand circuit.

Low, high, or erratic wire speed. Readjust front panel settings (see Section 5-1).

Change to correct size drive rolls (see Section 6-3).

Readjust drive roll pressure (see Section 4-15).

Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owners Manual).

Check position of input jumper links (see Section 4-11).



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OM-230 693 Page 32

Trouble Remedy

No wire feed. Turn Wire Speed control to higher setting (see Section 5-1).

Clear obstruction in gun contact tip or liner (see welding gun Owners Manual).

Readjust drive roll pressure (see Section 4-15).

Change to correct size drive rolls (see Section 6-3).

Rethread welding wire (see Section 4-15).

HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to coolallowing the fan to run. After unit is cool, If HL.P 002 message remains, contact Factory AuthorizedService Agent (see Section 6-2).

HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causingshort circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check forshorted trigger leads.

HL.P 005 appears on meters. Wire feed malfunction. Check wire feed delivery system.

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



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Notes


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SECTION 7 ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram


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243 035-A


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SECTION 8 MIG WELDING (GMAW) GUIDELINES

mig1 200912

Wire Feeder/Power Source

Workp