OM-1327
213 814X
2007−11
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
Millermatic 350 And
R
Millermatic 350P
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TABLE OF CONTENTS
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. Selecting A Location And Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-16. Selection A Location And Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-17. Threading Welding Wire For MIG Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-18. Threading Welding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro . . . . . . . . . . . . . 24
3-19. Threading Welding Wire Through XR Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-2. MIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-3. Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-4. Weld Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-5. MIG Gun-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-6. Pulse MIG Mode Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-7. Pulse MIG Gun-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-8. Tip Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-9. Weld Parameters For MIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-10. Weld Parameters For Pulse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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TABLE OF CONTENTS
SECTION 5 − PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-1. MIG Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-2. Pulse MIG Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5-3. Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill . . . . . . . . . . . . . . . . . . . . . . . . 33
5-5. Setting Hot Start (Aluminum Pulse Only) Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-6. Setting Crater Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-7. Recommended Crater Fill Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5-8. System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5-9. Motor Calibration Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-10. Set Up Push Motor Torque (SUP) Or Reset (rES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8-1. Drive Roll And Wire Guide Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
. Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
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Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
follow all Safety Standards.
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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.
Only qualified persons should install, operate, maintain, and
repair this unit.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
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Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.
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.
ELECTRIC SHOCK can kill.
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Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
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Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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Do not touch live electrical parts.
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
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 work
or ground.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
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Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Do not connect more than one electrode or work cable to any
single weld output terminal.
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Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
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Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC 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 welder
is recommended. And, do not work alone!
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Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
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Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
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To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
OM-1327 Page 1
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Do not use welder to thaw frozen pipes.
FUMES AND GASES can be hazardous.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
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Keep your head out of the fumes. Do not breathe the fumes.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
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If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
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Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
FLYING METAL or DIRT can injure eyes.
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Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
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Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
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Wear approved safety glasses with side
shields even under your welding helmet.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
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Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
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ImplantedMedical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
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Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
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Wear approved ear protection if noise level is
high.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
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Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
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Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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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.
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Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
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 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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Do not install unit near flammables.
D
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D
D
Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
FALLING UNIT can cause injury.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
READ INSTRUCTIONS.
Use equipment of adequate capacity to lift and
support unit.
D
D
Read Owner’s Manual before using or servic-
ing unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D
D
Allow cooling period; follow rated duty cycle.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Reduce current or reduce duty cycle before
starting to weld again.
D
Do not block or filter airflow to unit.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
FLYING SPARKS can cause injury.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D
D
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
If notified by the FCC about interference, stop using the
equipmentat once.
D
D
Have the installation regularly checked and maintained.
D
Sparks can cause fires — keep flammables away.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
D
D
Do not press gun trigger until instructed to do
so.
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.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OM-1327 Page 3
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1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044,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 10036–8002 (phone:
212-642-4900,website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
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-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
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).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 5060 Mississauga,
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-1327 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2007−04
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
. Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
2-2. Dangers relatifs au soudage à l’arc
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re-
commandée.En outre, ne pas travailler seul !
Les symboles représentés ci-dessous sont utilisés dans ce ma-
nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec-
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentationselon la norme OSHA 29 CFR 1910.147 (voir nor-
mes de sécurité).
Installer le poste correctement et le mettre à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
nationales,provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D
D
Seul un personnel qualifié est autorisé à installer, faire fonc-
tionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes,notamment les enfants de l’appareil.
D
D
En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
D
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D
D
Ne pas enrouler les câbles autour du corps.
D
D
Ne pas toucher aux pièces électriques sous tension.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Porter des gants isolants et des vêtements de protection secs et
sans trous.
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D
D
S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide dou-
blée.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil
conformémentà ce manuel.
D
D
Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D
D
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
D
D’autres consignes de sécurité sont nécessaires dans les condi-
tions suivantes : risques électriques dans un environnement
humideou si l’on porte des vêtements mouillés ; sur des structures
métalliquestelles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
D
Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.
D
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
OM-1327 Page 5
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Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a
coupé l’alimentation.
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
D
Arrêter les convertisseurs, débrancher le courant électrique et
déchargerles condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objets
métalliquespeut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D
Ne pas toucher à mains nues les parties
chaudes.
D
Prévoir une période de refroidissement avant de
travailler à l’équipement.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusementavec des protections homologués.
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
D
D
D
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereux pour votre santé.
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor-
mes de sécurité).
D
D
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais-
seurs.
D
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo-
quant des risques d’électrocution, d’étincelles et d’incendie.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
D
D
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
mer des gaz hautement toxiques et irritants.
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtementset tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
D
D
D
D
D
D
Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DES PIECES DE METAL ou DES SA-
LETES peuvent provoquer des bles-
sures dans les yeux.
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D
Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliquesvolantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D
Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
OM-1327 Page 6
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D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D
Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D
Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
d’air homologué.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux.
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou-
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction.
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D
D
D
D
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de sou-
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécu-
rité.
dage, les manipuler avec précaution.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
Porter un écran facial pour protéger le visage et
les yeux.
D
Ne pas installer l’appareil à proximité de pro-
duits inflammables.
D
Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuv-
re est à exécuter dans un endroit sûr lorsque l’on
porte l’équipement homologué de protection du
visage, des mains et du corps.
D
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentationest correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D
Les étincelles risquent de causer un incendie − éloigner toute sub-
stance inflammable.
LA CHUTE DE L’APPAREIL peut
blesser.
D
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Prévoir une période de refroidissement ; re-
specter le cycle opératoire nominal.
D
D
Ne pas s’approcher des organes mobiles.
D
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
Ne pas obstruer les passages d’air du poste.
OM-1327 Page 7
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LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipe-
ments de radio−navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Maintenirfermés et verrouillés les portes, pan-
neaux, recouvrements et dispositifs de protec-
tion.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D
L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et l’é-
quipement commandé par ordinateur tel que
les robots.
Remettreles portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
D
Veiller à ce que tout l’équipement de la zone de soudage soit
compatibleélectromagnétiquement.
D
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
D
N’utiliser que les pièces de rechange recom-
mandées par le constructeur.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentairestelles que le déplacement du poste, l’utilisation de câ-
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
D
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
2-4. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmesde procréation. Se laver les mains après manipu-
lation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
me provoquant des cancers et des malformations
congénitalesou autres problèmes de procréation.
OM-1327 Page 8
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2-5. Principales normes de sécurité
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, 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,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900,site Internet : www.ansi.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (téléphone
1-877-413-5184,site Internet : www.global.ihs.com).
:
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-
tilly, VA 20151 (téléphone
www.cganet.com).
:
703-788-2700, site Internet
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
CanadianStandards Association, 5060 Mississauga, Ontario, Canada
2-6. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir exa-
miné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiqueset champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-1327 Page 9
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SECTION 3 − INSTALLATION
3-1. Specifications
Max. Open
Circuit
Voltage
Amps Input at Rated Output
Rated Output
60 Hz
200 V
230 V
460 V
575V
KVA
KW
300 A at
32 VDC,
60% Duty
Cycle
350 A at
32 VDC,
40% Duty
Cycle
90
69
(1.7*)
61
(1.5*)
30
(0.75*)
24
(0.5*)
13.1
11.2
Single-Phase
Three-Phase
34
(1.7*)
30
(1.5*)
15
(0.75*)
12
(0.5*)
11.6
11.5
* While idling
Wire Type and Diameter
Stainless Steel
Wire Feed Speed
Dimensions
Net Weight
Solid Steel
Aluminum
50−700 IPM
(1.3−17.8 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
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
500
400
If unit overheats, thermistors open,
output stops, and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
300
250
225
200
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
150
100
10
15
20
25 30
40
50 60 70 80 90 100
% DUTY CYCLE
60% Duty Cycle At 300 Amperes
40% Duty Cycle At 350 Amperes
6 Minutes Welding
4 Minutes Resting
4 Minutes Welding
6 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
sduty1 5/95 / 217 442-A
OM-1327 Page 11
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3-3. Volt-Ampere Curve
1
Normal Volt-Ampere Curves
The volt-ampere curves show the
normal minimum and maximum
voltage and amperage output
capabilities of the welding power
source. Curves of other settings fall
between the curves shown.
MAX VOLTS
MIN VOLTS
90
80
70
60
50
40
30
20
10
0
0
50
100
150
200
250
300
350
AMPERAGE
217 443-A
3-4. Connecting To Weld Output Terminals
4
1
Do not place
anything between
weld cable terminal
and copper bar.
2
3
Tools Needed:
3/4 in (19 mm)
803 778-A
Correct Installation
Incorrect Installation
1
2
3
4
Weld Output Terminal
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar. Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
!
Turn off power before connecting to
weld output terminals.
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your ma-
chine.
Remove supplied nut from weld output ter-
minal. Slide weld cable terminal onto weld
OM-1327 Page 12
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3-5. Installing Work Clamp
1
2
Work Cable
Boot
Route cable through front panel
opening. Slide boot onto work
cable.
3
Negative (−) Output Terminal
Connect cable to terminal and
cover connection with boot.
Close door.
1
2
3
Tools Needed:
3/4 in
803 540-B
3-6. Installing Welding Gun/Cable Holder
1
2
3
Welding Gun/Cable Holder
Wrapper
Slots
2
Angle holder to insert hook through
bottom slot. Drop holder down so
that hook exits top slot.
3
1
Ref. 803 545-B / Ref. 803 539-B
OM-1327 Page 13
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3-7. Installing Welding Gun
1
2
3
Drive Assembly
Gun Securing Knob
Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly (make sure
gun end does not touch drive rolls).
Tighten knob.
4
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
4
3
2
1
Ref. 803 541-B
OM-1327 Page 14
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3-8. Connecting Spoolmatic) 15A Or 30A Gun
1
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
2
3
Weld Cable
Shielding Gas Hose
Route weld cable and gas hose
through opening in front panel.
4
Positive Weld Output Terminal
Connect weld cable to weld output
terminal.
5
Regulator/Flowmeter
1
Route shielding gas hose through
wire drive compartment, out
opening in rear panel, and up to
regulator/flowmeter. Connect gas
hose to regulator/flowmeter.
3
2
2
4
5
3
Tools Needed:
3/4, 5/8 in
803 568-C
OM-1327 Page 15
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3-9. Connecting XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro
.
XR Edge guns prior to serial no.
LE079101 require an adapter
cord (part no. 195 498).
1
2
3
Gun End
Gun Liner
Wire Outlet Guide
Trim excess liner from end of gun
so no more than 3/32 in (2.4 mm) of
liner extends past wire outlet guide.
4
Gun Securing Knob
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly (make sure
gun end does not touch drive rolls).
Tighten knob.
5
1
Be sure to change drive rolls to the
proper size and type.
5
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
.
Be sure to trim liner to proper extension.
3/32 in
(2.4 mm)
4
2
3
803 569-A / Ref. 803 570 -A / Ref. 803 463
OM-1327 Page 16
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3-10. Setting Gun Polarity For Wire Type
1
Polarity Changeover Information
Changing Polarity
Always read and follow manufacture’s
recommendedpolarity.
Wire Drive
Work Clamp Lead
Assembly Lead
D
1
D
+
-
Positive
Terminal
Negative
Terminal
Shown as shipped − Electrode Positive (DCEP): For
solid steel, stainless steel, aluminum, or flux core with
gas wires (GMAW).
Electrode Negative (DCEN): Reverse lead connections
at terminals from that shown above for gasless flux core
wires (FCAW). Drive assembly becomes negative.
3/4, 11/16 in
Ref. 803 541-A
OM-1327 Page 17
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3-11. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
1
2
1
2
Cap
Cylinder Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3
4
3
4
Cylinder
Regulator/Flowmeter
7
5
Install so face is vertical.
Argon Gas Or Mixed Gas
1
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
2
Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on
rear of welding power source.
3
7
Flow Adjust
8
9
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
CO Gas
2
manufacturer’s
recommended
flow rate.
8
9
CO Adapter (Customer
Supplied)
2
O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO
cylinder.
2
6
Rear Panel
Tools Needed:
1-1/8, 5/8 in
803 542-B
OM-1327 Page 18
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3-12. Installing Wire Spool and Adjusting Hub Tension
Use compression spring with
8 in (200 mm) spools.
When a slight force is needed to turn spool, tension is set.
Tools Needed:
15/16 in
072573-B
3-13. 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
60 Hz Three Phase
Input Voltage
200
69
230
61
460
30
575
24
200
34
230
30
460
15
575
12
Input Amperes At Rated Output
Max Recommended Standard Fuse Rating In Amperes
1
2
Circuit Breaker , Time-Delay
80
100
6
70
90
8
35
40
10
25
35
12
40
50
10
35
45
10
15
20
14
10
15
14
3
Normal Operating
4
Min Input Conductor Size In AWG
101
(31)
86
(26)
229
(70)
217
(66)
86
(26)
114
(35)
178
(54)
277
(85)
Max Recommended Input Conductor Length In Feet (Meters)
4
Min Grounding Conductor Size In AWG
8
8
10
12
10
10
14
14
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
NOTICE − This unit is either a 200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage
available at site to be sure it matches the voltage specified on the rating label.
OM-1327 Page 19
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3-14. Selecting Input Voltage (200/230/460 Volt Models Only)
Turn Off welding power
source, disconnect input
power, and check voltage on
input capacitors according
to Section 6-3 before
proceeding.
.
Be sure to reinstall all four screws
securing relinking board in place.
.
.
Check input voltage available
at site.
1
Incorrect linking can damage
unit and void the warranty.
1
Voltage Selection View
Window
Check voltage selected in unit.
Changing selection is only neces-
sary if selected value does not
match available input voltage.
2
3
4
Relinking Board PC6
Mounting Screws
Receptacle RC23
(Connection For 230 VAC
Input Power)
5
Receptacle RC46
(Connection For 460 VAC
Input Power)
Move relinking board as needed
and connect plug PLG32 (in unit) to
RC23 or RC46 according to input
power voltage.
3
4
2
3
5
Tools Needed:
5/16 in
803 539-B / 804 042-A
OM-1327 Page 20
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3-15. Selecting A Location And Connecting 3-Phase Input Power
3
Do not move or operate
unit where it could tip.
= GND/PE Earth Ground
5
8
3
18 in (457 mm)
for airflow
L1
L2
L3
7
4
6
1
2
Rear Panel
Tools Needed:
Ref. 803 543-D / 803 766-A
availableat site to be sure it matches conductor to disconnect device grounding
Installationmust meet all National and
Local Codes - have only qualified
persons make this installation.
the voltage specified on the rating
label.
terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
1
2
3
Rating Label
Disconnect and lockout/tagout input
power before connecting input
conductors from unit.
Input Power Cord
Disconnect Device (switch shown in
the OFF position)
8
Over-Current Protection
Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
4
Green Or Green/Yellow Grounding
Conductor
Select type and size of over-current
protection using Section 3-13 (fused
disconnect switch shown).
5
6
7
Disconnect Device Grounding Terminal
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
Warning: This unit is either
a
200/230/460ac input voltage model or
460/575 ac input voltage model. See
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
rating label on unit and check voltage Connect green or green/yellow grounding switch in the On position.
OM-1327 Page 21
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3-16. Selection A Location And Connecting 1-Phase Input Power
1
Do not move or operate
unit where it could tip.
9
=GND/PE Earth Ground
11
8
10
18 in (457 mm)
for airflow
L1
L2
3
5
3
4
5
1
2
6
7
Rear Panel
2
Tools Needed:
Ref. 803 543-D / 803 766-A
Three Conductor Power Cord Preparation
9
Disconnect Device Grounding Terminal
Installationmust meet all National and
Local Codes - have only qualified
persons make this installation.
1
2
3
Rating Label
10 Disconnect Device Line Terminals
Input Power Cord
Connect green or green/yellow grounding
grounding terminal first.
Disconnect and lockout/tagout input
power before connecting input
conductors form unit.
Black And White Input Conductors (L1
And L2)
4
5
Red Input Conductor
Connect input conductors L1 and L2 to
disconnect device line terminals.
Green Or Green/Yellow Grounding
Conductor
Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
11 Over-Current Protection
6
7
Insulation Sleeving
Electrical Tape
Warning: This unit is either
a
Select type and size of over-current protec-
200/230/460ac input voltage model or
460/575 ac input voltage model. See
rating label on unit and check voltage
availableat site to be sure it matches
the voltage specified on the rating
label.
switch shown).
Disconnect
Device
Input
Power
Connections
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
8
Disconnect Device (switch shown in
the OFF position)
OM-1327 Page 22
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3-17. Threading Welding Wire For MIG Gun
1
2
3
4
5
6
7
8
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Intermediate Wire Guide
Outlet Wire Guide
Pressure Adjustment Knob
Gun Conduit Cable
7
Lay gun cable out straight.
8
Tools Needed:
6
5
3
1
2
4
.
Hold wire tightly to keep
it from unraveling.
6 in
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
Tighten
.
Use pressure indicator scale to set
a desired drive roll pressure.
Pressure
Indicator
Scale
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip.
Turn On.
Tighten
1
2
3
4
WOOD
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-B / S-0627-A
OM-1327 Page 23
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3-18. Threading Welding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro
1
2
3
4
5
6
7
8
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Intermediate Wire Guide
Outlet Wire Guide
Pressure Adjustment Knob
Gun Conduit Cable
7
Lay gun cable out straight.
8
Tools Needed:
1
2
3
4
5
6
.
Hold wire tightly to keep
it from unraveling.
IMPORTANT!
For Aluminum Push−Pull welding.
Thread hub tension nut loosely
6 in
(150 mm)
218243−A
Pull and hold wire; cut off end.
Open pressure assembly.
IMPORTANT!
For Aluminum
Push−Pull welding.
Tighten
1
2
3
Pressure
Indicator
Scale
1
2
3
4
4
218244−A
Push wire thru guides into gun;
continue to hold wire.
Close and tighten pressure
assembly, and let go of wire.
.
Use pressure indicator scale to
set front drive roll pressure to 1
and rear drive roll pressure to
less than 1.
welding wire through XR guns.
Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A
OM-1327 Page 24
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3-19. Threading Welding Wire Through XR Guns
Welding wire is electrically live
when gun trigger is used to jog
wire.
For XR-A Edge Gun:
.
on feeding wire through welding pow-
er source.
1
1
Pressure Roll Assembly
Lay gun cable out straight.
Open top cover, and open pressure roll as-
sembly. If not already done, remove gun
barrel assembly.
Press gun trigger until about 4 in (102 mm)
of wire is sticking out front of gun. Insert
wire into barrel liner and tighten barrel as-
sembly. Install correct size contact tube
and install collet nut.
Turn On
Welding Power
Source.
Remove barrel assembly before
threading wire through gun.
Close top cover on gun. Press trigger
switch until about 6 in (152 mm) of wire is
sticking out end of contact tip. Cut off wire.
Close and latch door.
.
XR Edge gun drive roll pressure
should be set at minimum.
For XR-A Pistol Gun:
1
2
3
Pressure Roll Assembly
Drive Roll
2
3
Thumbscrew
Lay gun cable out straight. Open top
cover, and lift pressure arm and open
pressure roll assembly. If not already
done, remove gun barrel assembly.
Manually thread wire along drive roll
groove. Close pressure roll assembly.
Press gun trigger until about 4 in (102 mm)
of wire is sticking out front of gun. Insert
wire into barrel liner and tighten barrel as-
sembly. Install correct size contact tube
and install collet nut. Reinstall gun cover.
1
Turn On
Welding Power
Source.
4
Pressure Adjustment Knob
See final pressure adjustment at bottom of
page.
Remove barrel assembly
before threading wire
through gun.
For XR-A Pistol Gun:
Nonconductive
Surface
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close and latch door.
Turn welding power source Off.
Tools Needed:
.
Do not exceed midrange setting.
Ref. 802 193-A / 801 556 / Ref. 151 666-C
OM-1327 Page 25
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SECTION 4 − OPERATION
4-1. Controls
11
10
1
2
12
3
4
5
7
6
8
9
Ref. 213 935-A
1
Pulse Indicator Light
Use button to access Timers, Process and
Wire menus.
12 Weld Functions/Setup Indicator
Lights
.
Pulse only lights if unit has the pulse
MIG module and is programmed for
pulse MIG.
VOLTS illuminates in MIG welding mode
indicating volts in left display can be
adjusted. Also, VOLTS lights to indicate left
display is showing actual voltage during
welding and for 5 seconds after the arc is
extinguished.
7
Arc Control Button
Use button to select either inductance
control in MIG welding mode or Sharp Arc
in Pulse MIG welding mode.
2
MIG Indicator Lights
Pulse (1) and MIG (2) illuminate to Indicate
weld mode of unit.
8
Left Knob
ARC LENGTH illuminates in Pulse MIG
weldingmode indicating Arc Length can be
adjusted.
3
Process Light
Use knob to adjust volts in MIG welding
mode or change parameter values in
Setup.
PROCESS illuminates when unit is in
Process select menu.
SETUP illuminates when a parameter on
the corresponding display above the light
can be adjusted.
4
Wire Light
9
Right Knob
WIRE illuminates when unit is in Pulse MIG
program select menu.
WIRE SPEED illuminates in either Pulse
MIG or MIG welding mode indicating wire
speed can be adjusted.
Use knob to adjust wire speed in MIG
weldingmode or change parameter values
in Setup.
5
Timers Light
AMPS illuminates indicating welding amps
appears in the display, instead of wire
speed, during welding and for 5 seconds
after the arc is extinguished.
TIMERS illuminates when unit is in Timers
menu.
10 Left Display
11 Right Display
6
Setup Button
.
The first time the welding power source is energized it starts in MIG welding mode. Each time after the initial startup, when the unit is turned off,
whatever mode and parameter settings were last set will remain as the current settings the next time the unit is energized.
4-2. MIG Mode
In MIG mode, VOLTS is lit under left display and WIRE SPEED is lit under right display. Left knob is used to adjust
welding voltage within a range of 14-32 volts, and right knob is used to adjust wire feed speed within a range of 25-700
IPM. Refer to weld chart in front compartment for proper parameter settings according to wire type, shielding gas, and
material type and thickness.
4-3. Jog Mode
If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld
power. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow
OM-1327 Page 26
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because gas valve is located inside spool gun. For MIG guns, wire will feed for up to 2 minutes while trigger is pressed,
then wire drive system in unit will automatically shut off. For spool guns, wire will feed for up to 30 seconds before
shutting off. If gun trigger is pressed for 3 seconds without striking an arc the displays will show JOG MODE.
4-4. Weld Status
When trigger is released on a MIG gun, spool gun, or push-pull gun, the last actual amperage and voltage will be
shown on the displays for 5 seconds. The VOLTS and AMPS indicator lights will illuminate under the displays and each
value will appear in the corresponding display.
If a programmed value requires adjustment after the arc is extinguished and during the 5 seconds display of actual
values, turning either knob will cause actual values in the displays to be replaced by programmed values for
adjustment purposes.
.
The 5 second delay after the arc is extinguished for displaying actual weld values can be turned on or off in the Timer menu DISP selection (see
4-5. MIG Gun-On-Demand
The guns that can be used with this unit are MIG guns, spool guns, and push-pull guns. To switch from one gun to
another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is
pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun.
If the unit is powered down and back on again, the gun last used will become the current active gun.
4-6. Pulse MIG Mode Voltage Adjustment
In Pulse MIG mode there is no manual voltage adjustment; instead, voltage is synergically aligned with the proper wire
feed speed. Arc Length adjustment is used to adjust actual arc length which automatically adjusts the voltage. See
weld chart in front compartment for proper wire feed speed adjustment according to wire size and type.
4-7. Pulse MIG Gun-On-Demand
The spool gun functions slightly different in Pulse MIG mode. To switch from one gun to another, momentarily press the
trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data
and both displays will show the last programmed values for that particular gun. For a spool gun, the wire speed is taken
from the position of the gun potentiometer. This wire speed value is automatically adjusted if the potentiometer is
moved since the last time the gun was active. If the unit is powered down and back on again, the gun last used will
become the current active gun.
4-8. Tip Saver
If gun contact tip is directly shorted to the workpiece while gun trigger is pressed, the welding arc automatically shuts
off after 1 second to prevent wire burnback in the contact tip.
OM-1327 Page 27
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SECTION 5 − PROGRAMMING
5-1. MIG Welding Mode
1
2
3
4
7
5
6
8
9
Ref. 213 935-A
When the MIG light (2) is illuminated, the
unit is in MIG Welding mode.
Depress SETUP (6) button again to
illuminatethe WIRE (4) light. This menu is
not used in MIG Welding mode.
ARC CONTROL
MIG welding mode: Depress ARC
CONTROL (7) button to enter Arc control
menu and INDU will appear on the left
display and the corresponding setting will
appear on the right display. Adjust right
knob (9) to adjust inductance setting. In
MIG welding mode the Arc control is an
inductancecontrol from 0-99. Refer to MIG
welding chart for suggested Inductance
setting for the wire and gas types being
inductance will change the fluidity of the
puddle.
SETUP
Depress SETUP (6) button again to
illuminateTIMERS (5) light. For description
of the TIMERS, refer to TIMERS menu
To enter MIG welding mode, depress the
SETUP (6) button once to go to GUN
selection. Rotate the right knob (9) to select
the gun being used. Select MIG for standard
MIG gun, or select XR-A, EDGE, PYTH alpr
for push pull guns, or SPL for spoolgun.
If crater fill function menus are enabled,
TIMERS light will stay on to allow for adjust-
ment of crater parameters and timers (see
Depress SETUP (6) a second time to
illuminate the PROCESS (3) light. Rotate
right knob (9) until MIG is displayed (for MIG
only units NOT USED will be displayed).
Depress SETUP (6) button again to exit
menus and enter MIG welding mode.
OPERATION
Adjust welding Voltage with left knob (8)
and Wire Feed Speed with right knob (9).
Refer to MIG welding chart for proper
Voltage and Wire Feed Speed setting in
reference to material type, material
Low Inductance
Weld Bead
(0 setting)
High Inductance
Weld Bead
99 setting
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5-2. Pulse MIG Welding Mode
1
2
3
4
7
5
6
8
9
Ref. 213 935-A
When the PULSE MIG (1, 2) is illuminated,
the unit is in Pulse MIG Welding mode.
OPERATION
ARC CONTROL
Adjust right knob (9) for proper Wire Feed
speed and adjust left knob (8) to change
Arc Length if required. Arc length will de-
fault to 50 if never adjusted previously. Re-
fer to Pulse MIG welding chart for proper
Wire Speed setting for metal and metal
All Pulse MIG programs are setup with the
gases listed in the Pulse MIG welding
chart. If alternate gases are used, adjust
Arc Length and/or Sharp Arc (Arc Con-
trol) (7) to adjust arc characteristics.
Pulse MIG (1, 2) welding mode: Depress
ARC CONTROL (7) button to enter Arc
Control menu for sharp arc. SHRP will ap-
pear on the left display and the correspond-
ing setting will appear on the right display.
The setting can be adjusted from 0-50 and
all Pulse MIG welding programs are de-
signed with a setting of 25. Adjusting the
Sharp Arc setting will vary the width of the
welding arc cone.
SETUP
To enter Pulse MIG welding mode, depress
the SETUP (6) button once to go to GUN
selection. Rotate the right knob (9) to select
the gun being used. Select MIG for standard
MIG gun, or select XR-A, EDGE, PYTH alpr
for push pull guns, or SPL for spoolgun.
Depress SETUP (6) a second time to
illuminate the PROCESS (3) light. Rotate
right knob (9) until PULS is displayed.
Depress SETUP (6) button again to
illuminate the WIRE (4) light. Adjust left
knob (8) to select wire type, adjust right
knob (9) to select wire size.
ARC LENGTH
(0 Setting)
Low Setting
(50 Setting)
High Setting
Arc length can be adjusted from 0-99. All
Pulse MIG programs are set with a value of
50. Adjusting the Arc Length will vary the
length of the welding arc cone.
If a gas is used other than what is listed on
the Pulse MIG welding program chart, the
Sharp Arc can be adjusted to help custom-
ize your arc to the gas being used.
Depress SETUP (6) button again to exit
WIRE menu and enter TIMERS (5) menu.
The TIMERS (5) light will illuminate. For
description of the TIMERS, refer to
(0 Setting)
Low Setting
(99 Setting)
High Setting
If crater fill function menus are enabled,
TIMERS light will stay on to allow for adjust-
ment of crater parameters and timers (see
If a gas is used other than what is listed on
the Pulse MIG welding program chart, the
Arc Length can be adjusted to help custom-
ize your arc to the gas being used.
Depress SETUP (6) button again to exit
menus and enter PULSE welding mode.
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5-3. Timers
1
2
3
4
7
5
6
8
9
Ref. 213 935-A
To enter the TIMERS (5) menu depress the
SETUP (6) button 4 times or until the
TIMERS light (5) is illuminated.
depressed and before the welding arc will
be allowed to be active. Range of setting is
from 0-5 seconds.
Display (DISP) − Allows the Wire Speed
display to show actual welding amperage
while arc is active and for 5 seconds after
arc is shut off. Setting is either AMPS or
WFS for standard Wire Feed Speed.
Postflow (POST) − The amount of time that
the shielding gas will flow after the arc has
been shut off. Range of setting is 0-10
seconds.
Items that can be adjusted in this menu are:
Run-in speed (R-IN) − The speed of the
wire prior to the welding arc being struck.
This setting is a percentage of the Wire
Feed Speed the unit is set to for welding.
Programmingvalue ranges from 25-150.
Once in the TIMERS (5) menu, rotate the
left knob (8) to find a particular item, and ro-
tate the right knob (9) to change setting or
status.
Spot Timer (SPOT) − The amount of time
that the arc will be active before it shuts off
automatically. Range of setting is from
0-120 seconds. Spot timer is reset upon re-
lease of welding gun trigger.
Depress SETUP (6) button to get out of
TIMERS (5) menu and to enter welding
mode.
Preflow (PRE) − The amount of time that the
shielding gas will flow after the trigger is
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5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill
.
Accessing the Arc Times, Arc Starts, Hot Start (aluminum pulse only), and
Crater Fill data will also allow access to Software Version data and Motor
Calibrationfunction. The software version data and motor calibration func-
tion are for use by factory authorized service personnel only.
Do not use the motor calibration function if it appears on the displays.
2
1
3
4
Ref. 213 935-A
Arc times and number of arc starts are
saved in unit memory. To view this
information, press both SETUP (1) and
ARC CONTROL (2) buttons at the same
time.
To turn on the Crater Fill display, rotate left
knob (3) until CRTR appears in the left
display. The factory default for Crater Fill
display is OFF which appears in the right
display. Rotate the right knob (4) until ON
appears in the display.
.
The Crater Fill display can be turned
off after parameters are set in pro-
grams, but remember that once crater
fill is turned on in any program, it will
remainon even though it does not ap-
pear in the displays because Crater
Fill display is turned off.
Left display will initially show arc hours.
Rotate left knob (3) and display will change
to show number of arc starts.
To exit this menu, press either the SETUP
(1) or ARC CONTROL (2) button, or press
a
gun trigger on any welding gun
connected to the unit.
OM-1327 Page 33
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5-5. Setting Hot Start (Aluminum Pulse Only) Parameters
.
The factory default setting for Hot Start is “Auto” on 350P models. The Auto setting has
preset parameters. Hot Start can also be set to “On” (manual) for customized settings
or made inactive when set to Off.
2
1
3
4
Ref. 213 935-A
To access the Setup Feature Menu, press
both SETUP (1) and ARC CONTROL (2)
buttons at the same time.
Manual Hot Start Mode
Time range is 0.0-0.5 seconds for hot start
to be on.
When ALST appears in the left display and
STRL − Start Arc Length
On appears in the right display, the welding
power source is set for manual hot start
mode.
Range for start arc length is 0-99 that
changes arc length from shorter to longer.
Left display will initially show arc hours.
To access hot start parameters, press the
SETUP (1) button until SPWR appears in
the left display.
Rotate left knob (3) until ALST appears in
the left display.
RMPT − Ramp Time
Time range is 0.1-5.0 for the time it takes to
go from hot start to set wire feed speed.
Rotate right knob (4) to select hot start
mode as follows:
SPWR − Start Power
Range for start power is 100-250 as a per-
cent of wire feed speed.
.
The two parameters that will have the
largest influence on hot start are Start
Power and Start Time. These two pa-
rameters will determine how much
heat is provided and for how long at
the beginning of the weld.
Auto − default setting for preset hot start
parameters
.
SPWR maximum setting will depend
on set wire feed speed and may not
allow a setting of 250 under certain
conditions.
Off − hot start is inactive
On − allows customized setting of hot start
parameters
To exit this menu, press the SETUP (1)
button.
STMR − Start Time
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5-6. Setting Crater Fill
.
Crater parameters are welding gun independent (i.e. crater fill can be on for a spool
gun and off for a MIG gun). When using the same welding gun, MIG and pulse pro-
grams are independent of each other; however, crater parameters will be the same
for all pulse programs. For example, if a MIG gun is using the .035 steel pulse pro-
gram, and crater fill is on and parameters are set, crater will also be on and the
same parameters will be set for a stainless pulse program.
1
2
3
Ref. 213 935-A
To set Crater Fill, select a program and
press SETUP (1) until the TIMERS LED
turns on. Press SETUP again and the left
display will showCRTR and the right display
will show OFF.
Rotate left knob (2) to change display to
Rotate left knob (2) to change display to
TDLY for time delay. This setting is for spot
or skip welding without crater fill if the arc
time is less than the set time. Time range is
0.0-5.0 seconds (i.e. if TDLY is set for 2.0
seconds, weld operation will not go into
crater if gun trigger is released before 2.0
seconds).
TIME, and rotate right knob (3) to set crater
time. Time range is 0.1-5.0 seconds (see
Rotate left knob (2) to change display to
Rotate right knob (3) to turn crater ON.
VOLT (MIG program) or ARCL (pulse
program), and rotate right knob (3) to set
either volts (range is 10.0-32.0 volts) or arc
Rotate left knob (2) to change display to
WFS, and rotate right knob (3) to set crater
wire feed speed. Wire feed speed range is
To exit this menu, press the SETUP (1)
button.
OM-1327 Page 35
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5-7. Recommended Crater Fill Parameters
Recommended Crater Parameters
Suggested Suggested
Wire Types Shielding Gases
What Process
are You Using?
Wire Sizes
(Diameter)
What Material
are You Welding?
1/2"
(12.7mm)
M
I
G
P
U
L
S
E
OM-1327 Page 36
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3/8"
1/4"
3/16"
1/8"
19ga. 20ga.
(1.05mm)
(0.9mm)
SC-187 212-A
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5-8. System Reset
.
Accessing the System Reset function will also allow access to Timer Reset (RTMR)
and Option Reset (ORST) functions. The timer reset and option reset functions are
for use by factory authorized service personnel only.
Do not use the timer reset or option reset functions if they appear on the displays.
1
Ref. 213 935-A
A system reset function is available that
completely resets unit back to all the
original factory settings.
To apply the system reset function, press
SETUP (1) button, and wait until unit
completely reboots before performing any
other operations.
SRST will appear on the left display and OFF
will appear on the right display.
To prepare the unit for system reset, rotate
right knob until ON appears on the right
display.
To access this menu, turn on welding power
source, then press the SETUP (1) button
when the SETUP light illuminates under the
Left display.
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5-9. Motor Calibration Function
5
3
6
1
2
4
Ref. 213 935-A
Perform this function after replacing wire
drive motor and/or control circuit board.
3
4
5
6
Left Display
Press and hold gun trigger. Wire drive
speed will be overridden to 50 IPM for 12
seconds and then to 800 IPM for 12
seconds.
Right Knob
The
motor
calibration
function
Right Display
Arc Control Button
automatically calibrates the wire drive
motor to enhance arc starting performance
and consistency.
When CAL DONE appears on the display,
release gun trigger.
Open drive rolls in welding power source
and in push/pull gun if one is attached to
unit.
Data save will appear on the display while
the calibration data is being stored in the
Control board memory.
.
To obtain the most accurate
calibration, set up welding power
source in MIG welding mode.
Simultaneously press Setup and Arc
Control buttons.
Close drive rolls in welding power source and
push/pull gun.
Turn on unit input power.
Rotate left knob until MCAL is displayed.
Rotate right knob until YES is displayed.
1
2
Setup Button
Left Knob
This completes the motor calibration function,
and normal operation can resume.
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.
Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high.
5-10. Set Up Push Motor Torque (SUP) Or Reset (rES)
5
3
6
1
2
4
Ref. 213 935-A
1
2
3
4
5
6
Setup Button
Left Knob
(CCW) to find the particular item, and rotate
the right knob to change the setting.
Increasing this setting will increase the
over-torquelimit and speed up the remote
wire feed speed motor.
The following items can be adjusted by
rotating the left knob counterclockwise
(CCW):
Left Display
Right Knob
.
If Aluma-Pro push/pull gun has a
listed SUP value, set the power
source to match the SUP value.
Right Display
Arc Control Button
Set up Push Motor Torque (SUP) − This
feature is only active when a push/pull gun
is connected to the welding power source.
The (SUP) setting will adjust the
over-torque limit of the push motor inside
the welding power source. The range is
0-250 and the default value is 130.
To save settings and exit the (SUP) menu,
depress the gun trigger.
Simultaneously press Setup and Arc Control
buttons while turning on unit input power at
the power switch.
Reset (rES) − Rotate the right knob to
select ON. Press and release gun trigger to
reset system to factory default values.
Rotate the left knob counterclockwise
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SECTION 6 − MAINTENANCE &TROUBLESHOOTING
6-1. Routine Maintenance
Disconnect power
before maintaining.
.
Maintain more often
during severe conditions.
n = Check
Z = Change
~ = Clean
l = Replace
Reference
* To be done by Factory Authorized Service Agent
Every
3
Months
l Damaged Or Unreadable l Repair Or Replace
~ Clean And Tighten Weld n Check Gun Cable
Terminals
Labels
Cracked Weld Cable
Every
6
OR
Months
~ Inside Unit
Clean Drive Rolls
6-2. Overheating
Thermistors RT1 and RT2 protect the unit from damage due to overheating. If output diode heatsink or IGBT heatsink
gets too hot, RT1 and/or RT2 opens and output stops. The fan keeps running to cool the unit. Wait several minutes
before trying to weld.
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6-3. Measuring Input Capacitor Voltage
Significant DC voltage can
remain on capacitors after
unit is Off. Always check ca-
pacitors as shown to be sure
they have discharged before
working on unit.
Turn Off welding power source and
disconnect input power.
3
1
3
Remove case.
1
2
3
Input Capacitor C3 Terminals
Input Capacitor C4 Terminals
Voltmeter
2
Check input capacitors as shown.
Measure the dc voltage across the
positive (+) and negative (−)
terminalsuntil voltage drops to near
0 (zero) volts.
Proceed with job inside unit.
Reinstall case when finished.
Tools Needed:
5/16 in
221 044-A / Ref. 803 550-A
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6-4. Changing Drive Roll and Wire Inlet Guide
1
2
Securing Screw
Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
.045 Groove
.035 Groove
3
4
Intermediate Guide
Drive Roll
.
The drive assembly comes
equipped with factory
5
installed .035/.045 combina-
tion drive rolls. Be sure that all
4 drive rolls are installed cor-
rectly.
Stamped
.035
Stamped
.045
2
Combination drive rolls consist of
two different sized grooves. The
stamped markings on the end sur-
face of the drive roll refers to the
groove on the opposite side of the
drive roll. The groove closest to the
carrier gear is the groove for the
wire size viewed on the end surface
of the drive roll.
1
Install correct drive roll for wire size
and type.
.
U-Grooved drive rolls are re-
quired for feeding aluminum
wire.
4
Tools Needed:
5
Drive Roll Securing Nut
1
3
Turn nut one click to secure drive
roll.
5/64 in
7/16 in
802 520-B
OM-1327 Page 43
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.
6-5. Help Displays
V
A
A
A
A
A
A
A
A
V
A
A
A
HELP
0
1
2
3
4
5
6
7
HELP
8
9
V
V
HELP
HELP
V
V
HELP
HELP 10
V
A
V
HELP 11
HELP
V
V
A
HELP
TIP SAVE
V
A
V
HELP
MM 350P
V
A
V
HELP
MM 350
V
A
V
JOG XXX
HELP
Displays a jog wire feed speed.
OM-1327 Page 44
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.
S
Help 4
S
Help 9
.
All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
Indicates gun trigger was pulled and held for
2 minutes without a welding arc established
or there is a direct short between contact tip
or wire and the workpiece. Release gun
trigger and clear fault condition.
Indicates a malfunction in Pulse MIG
function. Check connection between pulse
board and user interface board. Replace
pulse board, if necessary.
S
Help 0
S
Help 10
Indicates overheating on left side of unit
(displays flash between OVER TEMP and
HELP 1). Unit will shutdown until internal
temperaturedrops within operational range.
S
Help 5
Indicates a trigger error when two gun
triggers are activated at the same time.
Release gun triggers to clear error.
Indicates a malfunction in wire feed system
and/or drive motor overcurrent condition.
Check for proper spool brake adjustment or
obstructions in wire feed system. Clean or
replace liner, wire guides, or contact tip.
S
Help 11
S
Help 1
Indicates a tach error when tach feedback
signal is not present. Release and press gun
trigger to reset tach signal. If error continues,
contact a Factory Authorized Service Agent.
Turn off primary input power and check input
voltage per primary voltage rating of welder,
and correct if necessary. If HELP 1 persists,
S
Help 6
Indicates a malfunction in wire feed system
and/or external drive motor overcurrent con-
dition (spool gun or push-pull gun). Check for
proper spool brake adjustment or
obstructions in wire feed system. Clean or
replace liner, wire guides, or contact tip.
this Indicates
a
communication error
between control board PC1 and user
interface board. Contact nearest Factory
Authorized Service Agent.
S
Tip Save
Indicates contact tip is directly shorted to
workpiece. Arc shuts off in this condition,
and message resets when tip is not touching
workpiece and gun trigger is released.
S
Help 2
S
Help 7
Indicates overheating on right side of unit
(displays flash between OVER TEMP and
HELP 2). Unit will shutdown until internal
temperaturedrops within operational range.
Indicates input voltage malfunction (voltage
too high or too low) causing unit to
automatically shut down. Turn off input
primary power and check input voltage per
primary voltage rating of welder. Unit will
operate once input voltage is within
specification and power to unit is turned off
and back on.
S
MM 350P
When unit is turned on, this display indicates
that pulse option is installed and operational.
S
Help 3
S
MM 350
When unit is turned on, this display indicates
that unit is either a MIG only machine or
pulse option is installed but not operational.
Indicates gun trigger was pulled and held
during power up. Release gun trigger and
clear fault condition. Also, this display can
Indicate no open circuit voltage detected
S
Help 8
S
Jog XXX (Wire Feed Speed)
when gun trigger is pulled and no arc Indicates a malfunction in the secondary
power circuit of the unit. Check control board Indicates trigger is pressed, but no arc is
detected within 3 seconds. Turn off primary
input power and contact
Authorized Service Agent.
a
Factory
PC1, and primary and secondary
connections.
detected. Wire feed speed goes to Jog wire
feed speed after 3 seconds.
SC-187 212-A
OM-1327 Page 45
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.
6-6. Troubleshooting
Trouble
Remedy
No weld output; wire does not feed.
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.
ThermistorRT1 or RT2 open (overheating). Allow fan to run; the unit will be enabled when it has cooled
Connect work clamp to get good metal to metal contact.
Replace contact tip (see gun Owner’s Manual).
Have Factory Authorized Service Agent check main control board and main rectifier.
Have Factory Authorized Service Agent check main control board and user interface board.
Low weld output.
Low, high, or erratic wire speed.
Replace inlet guide, contact tip, and/or liner if necessary (see gun Owner’s Manual).
Have Factory Authorized Service Agent check input voltage.
Have Factory Authorized Service Agent check main control board.
Clear obstruction in gun contact tip or liner (see gun Owner’s Manual).
No wire feed.
Check gun trigger and leads. Repair or replace gun if necessary.
Have Factory Authorized Service Agent check main control board and user interface board.
H − − message appears on voltmeter and ammeter displays to indicate thermistor RT1 or RT2 is open
OM-1327 Page 46
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Notes
OM-1327 Page 47
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224 242-B
OM-1327 Page 49
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Figure 7-2. Circuit Diagram For 460V/575V Models
OM-1327 Page 50
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223 926-B
OM-1327 Page 51
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SECTION 8 − PARTS LIST
8-1. Drive Roll And Wire Guide Kits
. Base selection of drive rolls upon the following recommended usages:
1
2
3
4
5
V-Grooved rolls for hard wire.
U-Grooved rolls for soft and soft shelled cored wires.
U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
V-Knurled rolls for hard shelled cored wires.
Drive roll types may be mixed to suit particular requirements (e.g. V-Knurled
roll in combination with U-Grooved).
Wire Diameter
Decimal
Drive Roll
Wire Guide
Kit No.
Fraction
.023/.025 in
.030 in
Metric
0.6 mm
0.8 mm
0.9 mm
Part No.
087 130
053 695
053 700
Type
Inlet
Intermediate
056 206
.023/.025 in
.030 in
087 132
046 780
046 781
V-Grooved
V-Grooved
V-Grooved
056 192
056 192
056 192
056 206
.035 in
.035 in
056 206
.045 in
.052 in
1/16 in
.045 in
.052 in
.062 in
1.2 mm
1.3 mm
1.6 mm
046 782
046 783
046 784
V-Grooved
V-Grooved
V-Grooved
056 193
056 193
056 195
056 207
056 207
056 209
053 697
053 698
053 699
.035 in
.045 in
.052 in
1/16 in
.035 in
.045 in
.052 in
1/16 in
.035 in
.045 in
.052 in
0.9 mm
1.2 mm
1.3 mm
044 750
046 785
046 786
046 787
046 792
046 793
046 794
046 795
U-Grooved
U-Grooved
U-Grooved
U-Grooved
V-Knurled
V-Knurled
V-Knurled
V-Knurled
056 192
056 193
056 193
056 195
056 192
056 193
056 193
056 195
056 206
056 207
056 207
056 209
056 206
056 207
056 207
056 209
072 000
053 701
053 702
.062 in
.035 in
1.6 mm
0.9 mm
053 706
132 958
.045 in
.052 in
.062 in
1.2 mm
1.3 mm
1.6 mm
132 957
132 956
132 955
Ref. S-0025-D
OM-1327 Page 52
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Notes
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Notes
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
APT & SAF Model Plasma Cutting Torches
Remote Controls
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
*
*
*
*
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
INCLUDING
ANY
IMPLIED
WARRANTY
OF
Running Gear/Trailers
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Plasma Cutting Torches (except APT & SAF
Models)
*
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
*
*
*
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co.2007−01
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