Miller Electric Welder Auto Axcess 450 User Manual
OM-210 540S  
Processes  
2007−10  
MIG (GMAW) Welding  
Pulsed MIG (GMAW-P)  
Flux Cored (FCAW) Welding  
Automatic Welding  
Description  
Automatic Welding Interface And  
Arc Welding Power Source  
Auto-Axcess™ 450  
Visit our website at  
File: Advanced Manufacturing Systems  
www.MillerWelds.com/ams  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
1
3
4
4
4
5
5
5
7
8
9
9
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
3-2. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
3-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
3-6. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
3-7. Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
3-8. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
3-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
3-10. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
3-11. Motor Control Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
3-12. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
3-13. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
3-14. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
3-15. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
3-16. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
4-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
4-2. Front Panel Controls (See Section 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24  
4-3. Front Panel Controls - Continued (See Section 4-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
4-4. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
4-5. Robot Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27  
4-6. Robot Auto-Calibration Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
4-7. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
SECTION 5 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
6-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
6-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
6-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
6-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34  
7-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34  
7-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35  
7-3. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38  
7-4. Process Control Module PC4 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
7-5. Diagnostic LED’s On Process Control Module PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
7-6. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
7-7. Diagnostic LED’s On Wire Feed Module PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
7-8. User Interface Module PC7 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
7-9. Diagnostic LED’s On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
7-10. Automation Interface Module PC9 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42  
7-11. Diagnostic LED’s On Automation Interface Module PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43  
7-12. Network And Module Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
7-13. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46  
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48  
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56  
WARRANTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
D
Always verify the supply ground − check and be sure that input  
power cord ground wire is properly connected to ground terminal in  
disconnect box or that cord plug is connected to a properly  
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  
found in the Safety Standards listed in Section 1-5. Read and  
follow all Safety Standards.  
D
D
D
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.  
D
D
D
D
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.  
D
D
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.  
D
Use only well-maintained equipment. Repair or replace damaged  
parts at once. Maintain unit according to manual.  
D
D
D
Do not touch live electrical parts.  
D
D
D
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.  
D
D
Insulate work clamp when not connected to workpiece to prevent  
contact with any metal object.  
D
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.  
D
D
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.  
D
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!  
D
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.  
D
D
Do not touch hot parts bare handed.  
Allow cooling period before working on gun or  
torch.  
D
D
Disconnect input power or stop engine before installing or  
servicing this equipment. Lockout/tagout input power according to  
OSHA 29 CFR 1910.147 (see Safety Standards).  
D
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-210 540 Page 1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
D
D
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.  
D
D
D
D
D
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.  
D
D
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.  
D
D
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.  
D
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.  
D
Welding, chipping, wire brushing, and grinding  
cause sparks and flying metal. As welds cool,  
they can throw off slag.  
D
D
Do not weld in locations near degreasing, cleaning, or spraying op-  
erations. The heat and rays of the arc can react with vapors to form  
highly toxic and irritating gases.  
D
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.  
D
D
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.  
D
Wearers of Pacemakers and other Implanted  
Medical Devices should keep away.  
D
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).  
D
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.  
D
D
D
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.  
D
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.  
D
D
Protect compressed gas cylinders from excessive heat, mechani-  
cal shocks, physical damage, slag, open flames, sparks, and arcs.  
D
Remove all flammables within 35 ft (10.7 m) of the welding arc. If  
this is not possible, tightly cover them with approved covers.  
Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
D
D
D
Do not weld where flying sparks can strike flammable material.  
Protect yourself and others from flying sparks and hot metal.  
D
D
D
D
D
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.  
D
D
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.  
D
Do not weld on closed containers such as tanks, drums, or pipes,  
unless they are properly prepared according to AWS F4.1 (see  
Safety Standards).  
D
D
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.  
D
D
Do not weld where the atmosphere may contain flammable dust,  
gas, or liquid vapors (such as gasoline).  
D
D
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-210 540 Page 2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
1-3. Additional Symbols For Installation, Operation, And Maintenance  
FIRE OR EXPLOSION hazard.  
MOVING PARTS can cause injury.  
D
Do not install or place unit on, over, or near  
combustiblesurfaces.  
D
D
Keep away from moving parts such as fans.  
Keep all doors, panels, covers, and guards  
closed and securely in place.  
D
Do not install unit near flammables.  
D
Do not overload building wiring − be sure power supply system is  
properly sized, rated, and protected to handle this unit.  
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-210 540 Page 3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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-  
site: www.nfpa.org.  
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:  
617-770-3000,website: www.nfpa.org and www. sparky.org).  
OSHA, Occupational Safety and Health Standards for General Indus-  
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,  
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-  
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-210 540 Page 4  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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-  
tion 2-5. Lire et observer toutes les normes de sécurité.  
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-210 540 Page 5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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  
provoquer des brûlures dans les  
yeux et 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  
SALETES peuvent provoquer des  
blessures 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-210 540 Page 6  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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-210 540 Page 7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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-210 540 Page 8  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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-210 540 Page 9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
OM-210 540 Page 10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 3 − INSTALLATION  
. Appearanceof actual unit may vary from unit shown in manual.  
3-1. Specifications  
Max  
Open  
Circuit  
Voltage  
DC  
Amperes Input At Rated Load Output 60 Hz,  
Three-Phase  
Rated  
Welding  
Output  
Wire Feed  
Speed  
Range**  
Wire  
Diameter  
Range  
Input  
Power  
Voltage  
Range  
Input  
kVA  
Input  
KW  
208 V  
230 V  
400V  
460 V  
575 V  
Three  
Phase  
450 A @  
44 V DC,  
100%  
10-44  
Standard:  
50-1400  
ipm  
.035-.062 in  
(0.8-1.6 mm)  
80  
67.0  
(0-1A*)  
59.0  
(0-1A*)  
34.0  
(0-1A*)  
29.0  
(0-1A*)  
23.0  
(0-1A*)  
23.8  
(0.8*)  
22.9  
(0.17*)  
Duty  
Cycle  
(1.3-35.6  
mpm)  
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.  
**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.  
3-2. Dimensions And Weight  
Hole Layout Dimensions  
E
22-1/2 in  
(572 mm)  
A
A
B
C
D
E
17-3/32 in (434 mm)  
17-3/8 in (441 mm)  
19-3/32 in (485 mm)  
16-3/32 in (409 mm)  
1/2 in (13 mm)  
31 in  
(787 mm)  
B
C
Weight  
17-3/32 in  
(434 mm)  
163 lb (74 kg) Net  
180 lb (82 kg) Ship  
D
Ref. 803 244-B  
OM-210 540 Page 11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-3. Duty Cycle And Overheating  
Duty Cycle is percentage of 10 min-  
utes that unit can weld at rated load  
without overheating.  
If unit overheats, thermostat(s)  
opens, output stops, and cooling  
fan runs. Wait fifteen minutes for  
unit to cool. Reduce amperage or  
duty cycle before welding.  
NOTICE − Exceeding duty cycle  
can damage unit and void warranty.  
100% Duty Cycle At 450 Amperes  
60% Duty Cycle At 580 Amperes  
6 Minutes Welding  
4 Minutes Resting  
ContinuousWelding  
Overheating  
0
A/V  
15  
OR  
Reduce Duty Cycle  
Minutes  
duty1 4/95 − 220 485-A  
3-4. Volt-Ampere Curves  
Volt-amperecurves show minimum  
and maximum voltage and  
amperage output capabilities of  
unit. Curves of other settings fall  
between curves shown.  
CV MODE  
80  
70  
60  
50  
40  
30  
20  
10  
0
. This  
volt-ampere  
represents the dynamic output  
of the unit with a static load.  
curve  
0
100  
200  
300  
400  
500  
600  
700  
AMPERAGE  
va_curve1 4/95 − 220 486-A  
OM-210 540 Page 12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-5. Selecting A Location  
Movement  
Tipping  
Do not move or operate  
unit where it could tip.  
2
OR  
1
Location  
Do not stack units. Beware of  
tipping.  
Special installation may be required where gasoline or volatile  
liquids are present − see NEC Article 511 or CEC Section 20.  
1
Lifting Forks  
4
Use lifting forks to move unit.  
Extend forks beyond opposite side  
of unit.  
3
2
Hand Cart  
Use cart or similar device to move  
unit.  
18 in  
(460 mm)  
3
Rating Label  
Use rating label to determine input  
power needs.  
4
Line Disconnect Device  
Locate unit near correct input  
power supply.  
18 in  
(460 mm)  
loc_2 3/96 -Ref. 803 244-B  
3-6. Connection Diagram  
. The proper interface kit must  
be installed in the welding  
power source/interface unit to  
allow it to be connected to the  
robot.  
5
2
3
4
1
Robot (Will Vary According To  
Application)  
1
2
3
4
5
6
7
8
Motor/Drive Assembly  
Gas Cylinder  
Gas Hose  
6
Robot Control  
7
Robot Input/Output Cable  
Gas And Motor Control Cable  
12  
Welding Power  
Source/Interface Unit  
9
Negative (−) Weld Cable  
10 Workpiece  
11 Voltage Sensing Lead  
Recommendedfor Accu-pulse and  
RMD (optional).  
10  
. Positive (+) voltage sensing  
lead is contained in the motor  
cable.  
8
11  
12 Positive (+) Weld Cable  
9
Ref. 803 244-B / Ref. 801 915-A  
OM-210 540 Page 13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-7. Rear Panel Receptacles And Supplementary Protectors  
1
115 V 10 A AC Receptacle RC2  
1
4
5
Receptacle supplies 60 Hz  
6
single-phase power. Maximum output  
from RC2 is limited by supplementary  
protector CB1 to 10 amps.  
2
3
Supplementary Protector CB1  
Supplementary Protector CB2  
2
3
CB1 protects 115 volt receptacle RC2  
from overload. If CB1 opens, RC2 does  
not work.  
CB2 protects the wirefeed motor from  
overload. If CB2 opens, the wirefeeder  
does not work.  
. Press button to reset breaker. If  
breaker continue to open, contact a  
Factory Authorized Service Agent.  
4
Wirefeed/Gas Receptacle RC8  
Use receptacle to connect gas and  
motor control cable to power source  
(see Sections 3-6 and 8 for additional  
information).  
5
PeripheralReceptacle RC25  
Receptacle provides connection to  
touch sensor, water flow switch, jog +/−,  
and I/O relay contacts circuitry (see  
Section 3-10).  
6
Robot Interface Receptacle RC72  
Use receptacle to connect robot  
input/output cable (see Sections 3-6  
and 8 for additional information).  
Ref. 803 245-B  
OM-210 540 Page 14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-8. Connecting To Weld Terminals  
. If using an electrode negative (straight polarity)  
process, the volt sense lead must be connected  
to the work.  
1
2
6
3
Do not place  
anything between  
weld cable terminal  
and copper bar.  
4
5
Tools Needed:  
3/4 in (19mm)  
Correct Installation  
Incorrect Installation  
Ref. 803 244-B / 803 778-A  
cable size.  
6
Copper Bar  
!
Turn off power before connecting to  
weld output terminals.  
1
2
Positive (+) Weld Output Terminal  
Negative (−) Weld Output Terminal  
Remove supplied nut from weld output  
terminal. Slide weld cable terminal onto  
weld 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.  
Failure to properly connect weld  
cables may cause excessive heat  
and start a fire, or damage your  
machine.  
Connect positive weld cable to Positive (+)  
weld terminal and negative (−) cable to  
Negative weld terminal.  
Determinetotal cable length in weld circuit  
(both positive and negative cables  
combined) and maximum welding  
amperes. See Section 3-9 to select proper  
3
4
5
Weld Output Terminal  
Supplied Weld Output Terminal Nut  
Weld Cable Terminal  
OM-210 540 Page 15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-9. Selecting Weld Cable Sizes*  
!
ARC WELDING can cause Electromagnetic Interference.  
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 electronic equipment. Be sure this welding machine is installed  
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving  
the welding machine, using shielded cables, using line filters, or shielding the work area.  
Weld Cable Size*** and Total Cable (Copper) Length in Weld Circuit  
Not Exceeding****  
350 ft  
(105  
m)  
400 ft  
(120  
m)  
150 ft  
(45 m)  
200 ft  
250 ft  
300 ft  
100 ft (30 m) or Less  
(60 m) (70 m) (90 m)  
Weld Output  
Terminals  
Turn off power before  
connecting to weld  
output terminals.  
10 − 60% 60 − 100%  
Welding  
Amperes**  
Duty  
Duty  
10 − 100% Duty Cycle  
Cycle  
Cycle  
Do not use worn, dam-  
aged, undersized, or  
poorly spliced cables.  
100  
150  
4 (20)  
3 (30)  
4 (20)  
3 (30)  
4 (20)  
2 (35)  
3 (30)  
1 (50)  
2 (35)  
1 (50)  
1/0 (60) 1/0 (60)  
3/0 (95) 3/0 (95)  
1/0 (60) 2/0 (70)  
2/0 (70) 3/0 (95)  
4/0  
(120)  
4/0  
(120)  
200  
250  
300  
350  
3 (30)  
2 (35)  
2 (35)  
1 (50)  
1 (50)  
1/0 (60)  
2/0 (70)  
3/0 (95)  
3/0 (95)  
4/0 (120)  
1/0 (60)  
2/0 (70)  
3/0 (95)  
4/0  
3/0 (95)  
2 ea. 2/0 2 ea. 2/0  
(2x70) (2x70)  
(120)  
4/0  
(120)  
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0  
(2x70) (2x95) (2x95)  
1 (50)  
1/0 (60)  
2/0 (70)  
4/0  
(120)  
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0  
(2x70) (2x95) (2x95) (2x120)  
1/0 (60)  
4/0  
(120)  
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0  
(2x70) (2x95) (2x120) (2x120)  
400  
500  
600  
700  
800  
1/0 (60)  
2/0 (70)  
3/0 (95)  
4/0 (120)  
4/0 (120)  
2/0 (70)  
3/0 (95)  
4/0 (120)  
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0  
(2x70) (2x95) (2x120) (3x95) (3x95)  
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0  
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)  
Positive  
)
Negative  
*
2 ea. 2/0  
(2x70)  
2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0  
(2x95) (2x120) (3x95) (3x120) (3x120) (4x120)  
Ref. 803 246-B  
2 ea. 2/0  
(2x70)  
2 ea. 3/0 2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0  
(2x95) (2x120) (3x120) (3x120) (4x120) (4x120)  
* This chart is a general guideline and may not suit all applications. If cable overheating occurs, use next size larger cable.  
**Cable should be sized for Peak Amperage (Apk) for pulse welding applications.  
***Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.  
2
( ) = mm for metric use  
****For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.  
S-0007-E  
. In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding  
characteristics with undersized cables. A recommendation for weld cable size is a minimum of 2/0 for 300 ampere welding power sources and  
4/0 for 450 ampere welding power sources when total cable length is less than 100 ft (30m).  
OM-210 540 Page 16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-10. Peripheral Receptacle Functions  
Function  
Socket  
Socket Information  
C
B
D
A
B
Not used.  
A
K
L
E
Not used.  
M
F
J
H
C*  
D
Circuit common.  
Purge  
Contact closure to C completes 40 volts dc  
solenoid circuit to purge shielding gas line.  
E
Contact closure to F indicates coolant flow switch is  
closed and recirculating coolant system is  
operational.  
Coolant Flow  
Switch Input  
Signal  
F*  
Circuit common.  
Jog  
H**  
Contact closure to circuit common advances  
welding wire at wire drive assembly.  
Retract  
J**  
K
Contact closure to circuit common retracts welding  
wire at wire drive assembly.  
Contact closure to L energizes Touch Sensor  
circuitry.  
Touch Sensor ON  
And Output Signal  
L*  
M
Circuit common.  
Part touched +24 volts dc output signal referenced  
to circuit common.  
Ref. 803 245-B  
*Circuit common is same electrical reference point.  
**Speed of Jog + (advance) and Jog − (retract) is 60 ipm for 3 seconds, then it automatically changes to 700 ipm.  
Note: A customer supplied matching amphenol plug, factory Part No. 194 847, [Amphenol Part No. 97-3106A-20-33P(B)(621) and strain relief  
clamp 97-3057-12(0621)] is required to use peripheral receptacle.  
OM-210 540 Page 17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-11. Motor Control Receptacle Functions  
Socket  
Socket Information  
C
G
A
F
J
A
Not used.  
E
B
K
D
B
C
D
E
F
Motor negative (−).  
Tach A.  
H
Motor positive (+).  
Tach common.  
Gas valve.  
G
H
J
Electrode sense.  
Tach +5 volts dc.  
Tach B.  
K
Gas valve.  
Ref. 803 245-B  
OM-210 540 Page 18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-12. Electrical Service Guide  
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-  
tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.  
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of  
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-  
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.  
. Actual input voltage should not exceed 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not  
be available.  
60 Hz Three Phase  
Input Voltage  
208  
67  
230  
59  
400  
34  
460  
29  
575  
23  
Input Amperes At Rated Output  
Max Recommended Standard Fuse Rating In Amperes  
1
2
3
Circuit Breaker , Time-Delay  
80  
100  
4
70  
90  
6
40  
50  
8
35  
45  
10  
25  
35  
10  
Normal Operating  
4
Min Input Conductor Size In AWG  
173  
(53)  
136  
(42)  
263  
(80)  
228  
(69)  
356  
(108)  
Max Recommended Input Conductor Length In Feet (Meters)  
4
Min Grounding Conductor Size In AWG  
8
8
8
10  
10  
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.  
OM-210 540 Page 19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-13. Connecting Input Power  
3
= GND/PE Earth Ground  
5
8
3
2
L1  
4
L2  
L3  
6
7
1
WARNING  
ELECTRIC SHOCK can kill;  
SIGNIFICANT DC VOLTAGE  
exists after removal of  
input power.  
S Always wait 5 minutes after power  
Is turned off before working on unit.  
S Check input capacitor voltage, and  
be sure it is near 0 before touching  
any parts.  
Read Owner’s Manual.  
Tools Needed:  
5/16 in  
Three-Phase Input Connection  
Route input power cable  
through tubing inside unit.  
Route ground conductor through  
current transducer to ground terminal.  
803 245-C / Ref. 803 766-A / 218 005-A  
applicable, use lugs of proper amperage Disconnect  
Device  
Input  
Power  
Turn Off welding power source, and  
check voltage on input capacitors  
according to Section 7-3 before  
proceeding.  
capacity and correct hole size.  
Connections  
Welding Power Source Input Power  
Connections  
3
Disconnect Device (switch shown in  
the OFF position)  
4
Green Or Green/Yellow Grounding  
Conductor  
2
Strain Relief  
Installation must meet all National  
and Local Codes − have only qualified  
persons make this installation.  
Install strain relief of proper size for unit and  
input conductors. Route conductors (cord)  
through strain relief and tighten screws.  
5
6
7
Disconnect Device Grounding Terminal  
Input Conductors (L1, L2 And L3)  
Disconnect Device Line Terminals  
Disconnect and lockout/tagout input  
power before connecting input  
conductors from unit.  
S
Use large strain relief for input conductor  
size 8 and larger.  
Connect green or green/yellow grounding  
conductor to disconnect device grounding  
terminal first.  
S
Use small strain relief with reducing  
!
Make input power connections to the  
welding power source first.  
washers for input conductor size 10.  
Connect input conductors as shown in  
illustration.  
Connect input conductors L1, L2, and L3 to  
disconnect device line terminals.  
Always  
connect  
green  
or  
green/yellow conductor to supply  
grounding terminal first, and never to  
a line terminal.  
Route green or green/yellow grounding  
conductor through current transducer and  
connect to welding power source grounding  
terminalfirst. Then connect input conductors  
L1, L2, and L3 to welding power source line  
terminals.  
8
Over-Current Protection  
Select type and size of over-current protec-  
tion using Section 3-12 (fused disconnect  
switch shown).  
1
Input Power Conductors (Customer  
Supplied Cord)  
Select size and length of conductors using  
Close and secure door on disconnect device.  
Section 3-12. Conductors must comply with Reinstall side panel onto welding power Remove lockout/tagout device, and place  
national, state, and local electrical codes. If source. switch in the On position.  
OM-210 540 Page 20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
3-14. Touch Sensor Operation  
The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source.  
The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral  
receptacle. Turning on touch sensor causes a dc voltage to be present on the welding wire. When welding wire  
touches the weldment, the voltage sensing circuit closes, and a +24 volts dc output signal is sent to the robot control  
indicating weldment detection. Touch sensor dc voltage on the welding wire is 80 volts DC. As soon as touch sensor  
turns on, WIRE LIVE appears on the front panel display.  
3-15. Remote Program Select  
. Remote Program Select is factory set to “On”. WaveWriter or File Management software is required to turn this function “Off”.  
When Remote Program Select is On, a remote device or robot pendant may be used to select programs. When Off,  
program selection must be done from the welding power source front panel.  
3-16. Remote Program Setting  
. When Remote Program Select is “On”, program selection will be determined by remote input once a weld is initiated. Prior to welding, program  
selection can be done in a normal manner from the welding power source front control panel.  
See the following table for the remote program select binary code.  
Program No.  
Output A  
Off  
Output B  
Off  
Output C  
Off  
1
2
3
4
5
6
7
8
On  
Off  
Off  
Off  
On  
Off  
On  
On  
Off  
Off  
Off  
On  
On  
Off  
On  
Off  
On  
On  
On  
On  
On  
OM-210 540 Page 21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SECTION 4 − OPERATION  
4-1. Operational Terms  
The following is a list of terms and their definitions as they apply to this interface unit:  
General Terms:  
Synergic  
Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual pulse  
settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed  
speed setting.  
Arc Adjust  
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual  
arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by volts in MIG  
programs.  
Program  
Process  
MIG  
Eight active slots for selection of various processes, wire types, and parameters.  
A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).  
CV weld process with individual settings of voltage and wire speed.  
Pulse  
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory  
taught data. Adaptive method is controlled by frequency adjustment.  
Accu-pulse  
Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds.  
Adaptive response is controlled by peak and minimum current levels. Benefits are shorter arc lengths, better  
puddle control, more tolerant of tip-to-work variation, less audible noise, no arc wandering, allows weld to fill in  
at toes increasing travel speed and deposition, and more tolerant to poor fit up and gaps.  
Accuspeed  
CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is designed to be  
tight and fast. Front panel display is ACCU − SPED.  
AccuCurve  
CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform. Has  
a distinguished change in arc characteristics. Front panel display is ACCU − CURV.  
RMD (optional)  
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of RMD are well  
suited to thin materials, improves gap filling and spatter reduction. Provides less heat input into workpiece,  
minimizes distortion and allows use of larger diameter wire on thin gauge materials.  
Wire Type  
Gas Type  
Process Set Up  
Program Load  
Volts  
Selection of wire type by alloys and classification.  
Selection of shielding gas being used in application.  
Selection procedure for entering program.  
Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).  
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.  
Time  
Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in the Arc On  
and Analog input or the Arc On and No Analog input modes).  
Arc Length  
WFS  
Distance from end of wire electrode to workpiece.  
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In  
pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power level on wire electrode  
(one knob control).  
Amps  
Indicates average amperage while welding and 3 seconds hold value at end of weld.  
Arc Control  
Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD  
(optional).  
Inductance  
Sharp Arc  
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per  
second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes  
the welding puddle more fluid.  
In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory  
pulse data. In RMD (optional) this control will affect the arc in much the same way as inductance.  
Adjust  
Control knob used to change or set parameters and functions.  
Sequence  
Selecting Sequence will allow setting of preflow, start, crater, postflow, and retract times and parameters (only  
available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes).  
Preflow  
Setting a time value for gas flow prior to arc start (only available on Auto Axcess models in the Arc On and  
Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File  
Management software).  
OM-210 540 Page 22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
4-1 . Operational Terms (Continued)  
Start  
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (only available on Auto Axcess  
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the  
optional PDA with File Management software).  
Weld  
Sequence function that allows for a timed weld operation [(0 to 999 seconds) only available on Auto Axcess  
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the  
optional PDA with File Management software].  
Crater  
Postflow  
Retract  
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends (only available on Auto Axcess  
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the  
optional PDA with File Management software).  
Setting a time value for gas flow after arc end (only available on Auto Axcess models in the Arc On and Analog  
input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File Manage-  
ment software).  
Sequence function that allows the wire to move back towards the contact tip when a welding operation is  
completed. Setting is both speed (IPM) and time (sec), (only available on Auto Axcess models in the Arc On  
and Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File  
Management software).  
Auto Thread  
Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously will  
automatically feed wire. Default setting is 72 inches at a feed rate of 700 ipm. Pressing jog, purge, or trigger  
switch will terminate the auto-threading feature. These values can be changed using a PDA with File  
Management/WaveWriter software.  
OM-210 540 Page 23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
4-2. Front Panel Controls (See Section 4-3)  
15  
14  
13  
1
4
12  
Program  
Volts  
Arc Adjust  
Wire Speed  
Amps  
11  
10  
3
Process  
Wirefeed  
Gas  
Wire Type  
Gas Type  
Contactor  
5
6
8
9
7
Setup  
Adjust  
Arc Control  
2
. When an LED is lit, it means the related function is active.  
198 993  
1
Program Display  
Displays the number of the active program.  
Adjust Knob  
PDA with File Management/WaveWriter Gas Type LED  
software. Program name is shown in upper  
and lower displays (items 13 and 15).  
When this LED is lit, turn the Adjust knob to  
select the desired weld gas. Gas type choices  
vary according to the selected weld process.  
2
5
Setup Mode Indicators  
Turn the Adjust knob to change program  
number, Setup, Arc Control, and weld  
parameters.  
The lit LED indicates which setup mode is  
active. Setup mode parameters are shown in  
Display Windows (see Items 13 and 15).  
See Table 4-1 for all gas abbreviations.  
6
Setup Push Button LED  
3
Program Push Button LED  
The LED lights to indicate one of the setup  
modes is active.  
Process LED  
The LED lights when the Program Push  
Button is active.  
When this LED is lit, turn the Adjust knob to  
select the desired weld process. Choices  
7
Setup Push Button  
4
Program Push Button  
include pulse welding (displayed as PULS), Press button to select Process, Wire Type,  
Accu-pulse, MIG welding (MIG), and Accu Wire Diameter, or Gas Type parameters.  
Puls/RMD [Regulated Metal Deposition  
Press push button (LED lights) and turn Adjust  
knob to select active program.  
The letter C is displayed with the program  
numberif the program has been changed from  
the factory settings using the optional PDA  
with File Management/WaveWriter software  
(see File Management/WaveWriter Owner’s  
Manual).  
. In order for selections to be retained in  
memory, the Setup push button must be  
pressed six times before any other push  
button is pressed: once to select Process,  
again to select Wire Type, again to select  
Wire Alloy, again to select Wire Size,  
again to select Gas Type, and a sixth time  
to store selections in memory. The  
displays will temporarily show “PROG  
LOAD” to indicate the data is being stored  
in memory.  
(optional)].  
Wire Type LED  
When this LED is lit, turn the Adjust knob to  
select the desired wire type, wire alloy, and  
size. Wire type and size choices vary  
according to the selected weld process.  
Choices may include steel (displayed as  
STL), stainless steel (SS), metal core  
. The program cannot be changed through  
the front panel while welding.  
Press and hold button to see program name. (MCOR), aluminum (ALUM). See Table 4-1  
Custom programs are named using optional for all wire abbreviations.  
OM-210 540 Page 24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
4-3. Front Panel Controls - Continued (See Section 4-2)  
8
Arc Control LED  
11 Wire Speed And Amps LED’s  
was used to set the unit in the ”Display  
Command Values” mode. In the Display  
Command Values mode, command  
values are displayed while welding.  
The LED lights to indicate the Arc Control The lit LED indicates whether wire speed or  
button is active. Light goes out when button is amps are being displayed.  
inactive.  
12 Wire Feed Speed/Amps Display Push  
. If a PDA with File Management/WaveWriter  
software is used to change wire feed units  
(IPM, MPM) or display welding information  
(command or actual),save the changes and  
then turn the power to the unit off and then  
on again for the changes to be carried out  
by the unit.  
9
Arc Control Push Button  
Button  
13 Lower Display  
This push button allows fine tuning inductance  
for MIG programs, and Arc Control for  
programs other than MIG. When the push  
button is pressed, the upper display (item 15)  
shows INDU for inductance, or ARC for Arc  
Control to indicate which parameter is  
selected for change. The range of possible  
values is 0-99 for inductance, and 0-50 for arc  
control. Turn the Adjust knob to change the  
parameter value. Press button to deactivate  
arc control mode (LED goes out).  
Press Wire Feed Speed/Amps Display button  
to show weld amperage or wire feed speed in  
lower display (the applicable LED under the  
lower display lights to indicate which is  
shown). When welding, actual value is shown.  
14 Volts And Arc Adjust LED’s  
If amperage was selected for display, the unit  
will show actual welding amperage prior to  
and while welding unless the the unit is in  
Display Command Values mode. Only wire  
speed command will be displayed while  
welding if the unit is set in Display Command  
Values mode, even if the Wire Feed  
Speed/AmpsDisplay button is pressed.  
The lit LED indicates whether voltage or arc  
length is being displayed.  
15 Upper Display  
The upper display shows different information  
depending on the active function of the unit  
and the weld process being used. When the  
display shows voltage (for a MIG process),  
the Volts LED lights. When it shows arc adjust  
[for a pulsed and RMD (optional) weld  
10 Wire Feed/Gas/Contactor LEDs  
The Wirefeed LED lights when the wire feeder  
is energized. For example, when the front  
panel Jog or Retract button is pressed, the  
Wirefeed LED lights.  
. Displays show actual or command values  
as determined by configuration menu process], the Arc Adjust LED lights. However,  
when using a PDA with File Management/ during any weld process (MIG and pulse), the  
WaveWriter software. Command values unit will display actual arc voltage unless a  
are displayed prior to welding and actual PDA with File Management/WaveWriter  
values are displayed while welding unless software has set the unit in the ”Display  
a PDA with File Management software CommandValues” mode.  
The Gas LED lights when the gas valve is  
energized.  
The Contactor LED lights when the output  
contactor is energized, making the weld  
output terminals live.  
Table 4-1. Welding Wire And Gas Abbreviations*  
Wire Description Wire Abbreviation  
Alloy Type  
Gas Type  
100% CO ,  
90% Argon/10% CO ,  
85% Argon/15% CO ,  
75% Argon/25% CO ,  
Gas Abbreviation  
Steel  
STL  
E70, E100, E120  
CO2  
C10  
C15  
C25  
C5  
2
2
2
2
95% Argon/5% CO ,  
2
95% Argon /5% O ,  
OX5  
OX2  
2
98% Argon/2% O  
2
Stainless Steel  
SS  
308, 309, 312, 316  
98% Argon, 2% O  
OX2  
Tri Gas  
2
(81Ar/18HE/1CO  
Accu-pulse)  
2
90HE/7-1/2Ar/2-1/2CO  
Tri Gas  
2
MIG/RMD/Accu-pulse)  
Cored Tubular Wire  
Aluminum  
MCOR  
ALUM  
71, 76, 86R, 409,  
439  
90% Argon/10% CO  
C10  
OX2  
2
98% Argon/2% O  
100% Argon  
2
4XXX, 5XXX  
ARGN  
* Not all wire types may be available with your unit.  
OM-210 540 Page 25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Table 4-2. Robot Abbreviations  
Manufacturer  
ABB  
Robot Abbreviation  
ABB  
Fanuc  
FANU  
Daihen  
DAHN  
Kawasaki  
Kuka  
KAWA  
KUKA  
Comau  
COMU  
HCHI  
Hitachi  
Nachi  
NCHI  
Panasonic  
Motorman  
Robot Adapter  
Detect Disabled  
None  
PANA  
MOTO  
DTEC  
OFF  
Robt DTEC  
4-4. Front Panel Switches  
6
3
4
8
5
1
9
7
2
Ref. 803 246-B  
1
Power Switch  
AUTO  
450  
6
Wirefeed LED  
Turns unit On or Off.  
Wirefeed LED illuminates when wire feeds or  
retracts.  
The power-up sequence may last up to 30  
seconds before the unit is ready to weld.  
During power-up, the front panel will display  
messages indicating the status of the unit. The  
first message is:  
AUTO 450 indicates the software being  
loaded.  
7
Retract Push Button  
2
Contactor LED  
Contactor LED illuminates when weld output is  
energized.  
Press button to retract wire. Wirefeed LED  
illuminates when Retract push button is  
pressed.  
NET  
WAIT  
3
Purge Push Button  
Press button to purge gas line.  
4 Gas LED  
NET WAIT is an abbreviation for ”network  
updating” and means the internal control  
network is powering up. The next message is  
Auto-Threading feature is activated by  
pressing the Jog and Retract buttons  
simultaneously. Pressing the Jog, Purge, or  
trigger switch will turn off the Auto-Threading  
feature.  
XXXX (Robot Type)  
XXXX identifies the robot adapter being used  
as identified by the unit (see Table 4-2 for a list  
of robot adapters that could be displayed). To  
ensure proper operation of the system, verify  
the robot displayed corresponds to the actual  
robot being used. The final message is  
Gas LED illuminates when Purge push button  
is pressed.  
8
9
PDA Port  
PC Port  
5
Jog Push Button  
Press button to jog wire.  
OM-210 540 Page 26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
4-5. Robot Calibration Mode  
Use the robot calibration mode to  
custom-calibratethe power source to  
the robot command signals. This  
ensures the wire speed, voltage, and  
arc adjust are the same on the robot  
pendantas on the power source.  
XXXX  
. The factory recommendation is to  
perform the calibration on all  
installationsor code updates.  
Follow this procedure if the factory  
settings are not as accurate as  
desired. Synchronization of the robot  
and power source signals makes  
installation easier and improves the  
operationof the system.  
Turn unit On. Unit displays abbreviated name of robot  
detected where XXXX appears (see Table 4-2 for a list  
of robot adapters that could be displayed).  
. The robot pendant must have  
Weld enabled, and there can be  
no start/stop crater conditions set  
in the robot.  
The calibration mode will execute as a  
”dry run” from the operator’s  
perspective. The welding power  
source provides the robot with  
feedback so the robot thinks a weld is  
underway, yet the robot torch need not  
move during the calibration.  
. If you wish to stop the calibration  
procedure, turn unit input power  
off and then on again.  
To enter calibration mode while robot name appears on front panel,  
press and hold wire feed/amps button until “ROBT CAL” appears on  
front panel. “ROBT CAL” message will not display until after the  
power-up sequence is completed (approximately 20 seconds).  
If the calibration is performed correctly  
the ROBT CAL message stops being  
displayed; however, if it is performed  
incorrectly, the message remains on  
the display.  
To start the calibration procedure over  
again, turn unit input power off and  
then on again following the calibration  
setup steps following the calibration  
setup steps.  
CIRCULER  
Use robot pendant or other method to enter two weld schedules into the  
robot. Maintain schedule 1 for at least 10 to 20 seconds minimum before  
moving on to schedule 2. Maintain schedule 2 for 10 to 20 seconds  
before ending the simulated weld. Schedule data is shown below:  
Schedule 1  
Schedule 2  
10.0 Volts  
100 IPM  
44.0 Volts  
1000 IPM  
When the robot calibration mode ends, the ROBT CAL message  
stops and the unit will display normal front panel information.  
198 993  
OM-210 540 Page 27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
4-6. Robot Auto-Calibration Sample Programs  
. It is critical to make certain that NO start power, start conditions, run-in, or crater parameters of any kind are present in the robot program. The  
welding power source is looking for 2 distinct welding conditions. If there is a “start power” condition, the welding power source will equate this  
as the first condition and fail to execute Auto-Cal correctly. If there is a “crater fill” condition, the welding power source will equate this as the second  
condition and fail to execute Auto-Cal correctly.  
Actual Motoman Welder Condition File  
<Welding Current Output Char.>  
NO.  
01  
REF (V)  
0.01  
MEASURE (A)  
1
02  
7.00  
500  
999  
000  
03  
13.99  
0.00  
04  
<Welding Voltage Output Char.>  
NO.  
01  
REF (V)  
0.14  
MEASURE (V)  
0.5  
02  
7.00  
25.0  
50.0  
03  
14.00  
04  
Sample Auto-Calibration Routine For Motoman Robot  
0000 NOP  
0001 Mov J  
0002  
AWELD 1.40  
(AWELD direct input of 1.40Volts = 100 ipm)  
(VWELD direct input of 2.80Volts = 10.0 volts)  
0003 VWELD 2.80  
0004 Arcon  
0005 Timer T=10.00  
0006 Arcof  
0007 AWELD 14.00  
0008 VWELD 12.32  
0009 Arcon  
(AWELD direct input of 14.00Volts = 1000 ipm)  
(VWELD direct input of 12.32Volts = 44.0 volts)  
0010 Timer T=10.00  
0011 Arcof  
0012 End  
OM-210 540 Page 28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Sample Auto-Calibration Routine For Fanuc Robot  
1: Call Safehome  
2: J P[1] 40% Fine  
Arcstart [10.0Volts, 100.0IPM]  
3: L P[2] 10.0 sec Fine  
Arc End [0.0Volts, 0.0IPM, 0.0Sec]  
4: Wait 1.00 (Sec)  
5: J P[3] 40% Fine  
Arcstart [44.0Volts, 1000.0IPM]  
6: L P[4] 10.0 sec Fine  
Arc End [0.0Volts, 0.0IPM, 0.0Sec]  
7: Call Safehome  
Sample Auto-Calibration Routine For ABB Robot  
Move J home, v500, z50, tweldgun;  
Arcl \ on, *, v500, sm1, wd1, wv0, z50, tweldgun;  
Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;  
WaitTime 5;  
Arcl \ on, *, v500, sm1, wd2, wv0, z50, tweldgun;  
Arcl \ off, *, v500, sm1, wd2, wv0, z50, tweldgun;  
Move J home, v500, z50, tweldgun;  
*Seam Data values must all be set at zero.  
Weld Data 1:  
weld_sched:=0  
Weld Data 2:  
weld_sched:=0  
weld_speed:=5  
weld_speed:=5  
weld_voltage:=10  
weld_wfs:=100  
weld_voltage:=44  
weld_wfs:=1000  
org_weldspeed:=0  
org_weldvoltage:=0  
org_weldwfeed:=0  
org_weldspeed:=0  
org_weldvoltage:=0  
org_weldwfeed:=0  
OM-210 540 Page 29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
4-7. Reset Mode  
. Reset mode is not active when  
Program Lock is enabled.  
RST  
NO  
The reset mode allows the operator to  
reload factory program settings for all  
eight active programs in the unit.  
. System configuration data will be  
lost during the Reset operation.  
Enter reset mode by turning power On and pressing  
the Program Push Button until the RST NO message  
is displayed. RST NO message will not display until  
after the power-up sequence is completed  
(approximately 20 seconds).  
RST  
YES  
RST  
CYCL  
PWR  
YES  
Press the Arc Control button to  
confirm the reset.  
Cycl Pwr message appears on the display  
when programs complete loading.  
Rotate Adjust knob to change NO  
to YES.  
The reset message is displayed for  
2 seconds while factory program  
settings are being reloaded.  
Turn power off, wait 10 seconds, and turn  
power back on again to complete the reset  
operation.  
During the reset mode the following  
factory default programs are loaded  
into the unit:  
. After Reset is complete, be sure to load  
appropriate programs that contain the  
correct wire size, process, and shielding gas  
for the welding operation  
Program 1  
Program 2  
Program 3  
Program 4  
Program 5  
Program 6  
Program 7  
Program 8  
Pulse  
.035 Mild Steel  
90% Argon, 10% CO  
2
MIG  
.035 Mild Steel  
75% Argon, 25% CO  
2
Accu-pulse  
.035 Mild Steel  
90% Argon, 10% O2  
Pulse  
.045 Mild Steel  
90% Argon, 10% CO  
2
MIG  
.045 Mild Steel  
75% Argon, 25% CO  
2
Accu-pulse  
.045 Mild Steel  
90% Argon, 10% O2  
Pulse  
.052 Mild Steel  
90% Argon, 10% CO  
2
MIG  
.052 Mild Steel  
75% Argon, 25% CO  
2
198 993 / 803 246-B  
OM-210 540 Page 30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SECTION 5 − MAINTENANCE  
5-1. Routine Maintenance  
. Maintain more often  
Disconnect power  
before maintaining.  
during severe conditions.  
n = Check  
Z = Change  
~ = Clean  
l = Replace  
Reference  
* To be done by Factory Authorized Service Agent  
Every  
3
l Unreadable Labels  
~ Weld Terminals  
l Damaged Gas Hose  
nl Weld Cables  
Months  
nl Cords  
nl Gun Cables  
OR  
Every  
6
Months  
~ Drive Rolls  
~ Inside Unit  
5-2. Blowing Out Inside Of Unit  
Do not remove case when  
blowing out inside of unit.  
To blow out unit, direct airflow  
through front and back louvers as  
shown.  
Ref. 803 244-B  
OM-210 540 Page 31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING  
Protect yourself and others from injury — read and follow these precautions.  
6-1. Symbol Usage  
OM-210 540S - 2007−10, safety_stm 2007−04  
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.  
6-2. Servicing Hazards  
FIRE OR EXPLOSION hazard.  
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.  
D
D
Do not place unit on, over, or near combustible  
surfaces.  
Do not service unit near flammables.  
Only qualified persons should test, maintain, and repair this  
unit.  
During servicing, keep everybody, especially children, away.  
FLYING METAL or DIRT can injure eyes.  
D
D
Wear safety glasses with side shields or face  
shield during servicing.  
ELECTRIC SHOCK can kill.  
Be careful not to short metal tools, parts, or  
wires together during testing and servicing.  
D
D
Do not touch live electrical parts.  
Turn Off welding power source and wire feeder  
and disconnect and lockout input power using  
line disconnect switch, circuit breakers, or by removing plug from re-  
ceptacle, or stop engine before servicing unless the procedure spe-  
cifically requires an energized unit.  
HOT PARTS can cause severe burns.  
D
D
Do not touch hot parts bare handed.  
D
Insulate yourself from ground by standing or working on dry insulat-  
ing mats big enough to prevent contact with the ground.  
Allow cooling period before working on  
equipment.  
D
D
Do not leave live unit unattended.  
D
To handle hot parts, use proper tools and/or  
wear heavy, insulated welding gloves and  
clothing to prevent burns.  
If this procedure requires an energized unit, have only personnel  
familiar with and following standard safety practices do the job.  
D
D
When testing a live unit, use the one-hand method. Do not put both  
hands inside unit. Keep one hand free.  
EXPLODING PARTS can cause injury.  
Disconnect input power conductors from deenergized supply line  
BEFORE moving a welding power source.  
D
D
Failedparts can explode or cause other parts to  
explode when power is applied to inverters.  
SIGNIFICANT DC VOLTAGE exists after removal of  
input power on inverters.  
Always wear a face shield and long sleeves  
when servicing inverters.  
D
Turn Off inverter, disconnect input power, and discharge input  
capacitors according to instructions in Troubleshooting Section be-  
fore touching any parts.  
SHOCK HAZARD from testing.  
D
Turn Off welding power source and wire feeder  
or stop engine before making or changing me-  
ter lead connections.  
STATIC (ESD) can damage PC boards.  
D
D
Put on grounded wrist strap BEFORE handling  
boards or parts.  
D
D
Use at least one meter lead that has a self-  
retainingspring clip such as an alligator clip.  
Use proper static-proof bags and boxes to  
store, move, or ship PC boards.  
Read instructions for test equipment.  
OM-210 540 Page 32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
OVERUSE can cause OVERHEATING.  
FALLING UNIT can cause injury.  
D
D
Allow cooling period; follow rated duty cycle.  
D
D
D
Use lifting eye to lift unit only, NOT running  
gear, gas cylinders, or any other accessories.  
Reduce current or reduce duty cycle before  
starting to weld again.  
Use equipment of adequate capacity to lift and  
support unit.  
D
Do not block or filter airflow to unit.  
If using lift forks to move unit, be sure forks are  
long enough to extend beyond opposite side of  
unit.  
H.F. RADIATION can cause interference.  
D
High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
D
Have only qualified persons familiar with  
electronic equipment install, test, and service  
H.F. producing units.  
MOVING PARTS can cause injury.  
D
D
Keep away from moving parts such as fans.  
D
D
The user is responsible for having a qualified electrician prompt-  
ly correct any interference problem resulting from the installa-  
tion.  
Keep away from pinch points such as drive  
rolls.  
D
Have only qualified persons remove doors,  
panels, covers, or guards for maintenance as  
necessary.  
If notified by the FCC about interference, stop using the  
equipmentat once.  
D
D
Have the installation regularly checked and maintained.  
D
D
Keep hands, hair, loose clothing, and tools  
away from moving parts.  
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.  
Reinstall doors, panels, covers, or guards  
when maintenance is finished and before re-  
connecting input power.  
READ INSTRUCTIONS.  
MAGNETIC FIELDS can affect Implanted  
Medical Devices.  
D
D
D
Use Testing Booklet (Part No. 150 853) when  
servicing this unit.  
D
Wearers of Pacemakers and other Implanted  
Medical Devices should keep away from serv-  
icing areas until consulting their doctor and the  
device manufacturer.  
Consult the Owner’s Manual for welding safety  
precautions.  
Use only genuine replacement parts from the  
manufacturer.  
6-3. 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.  
6-4. 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-210 540 Page 33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SECTION 7 − TROUBLESHOOTING  
7-1. Set Value Mode  
Program  
Volts  
Arc Adjust  
Wire Speed  
Amps  
4
Process  
Wirefeed  
Gas  
Wire Type  
Gas Type  
Contactor  
1
2
Setup  
Adjust  
Arc Control  
3
The Set Value mode is a troubleshooting tool Enter the Set Value mode by pressing the changed in the bottom display. Press the Wire  
Setup and Arc Control push buttons at the  
Feed Speed/Amps push button to toggle  
that allows certain robot command values to  
be manually over-ridden.  
same time. When in the Set Value mode the between selecting information in the top  
display windows briefly shows SET VALU and display or bottom display. The LED under the  
the blinking LED’s under the display windows active display will blink to indicate the value  
indicate whether Volts, Arc Adjust, or Wire that can be changed.  
1
2
3
4
Setup Push Button  
Arc Control Push Button  
Adjust Knob  
Speed can be changed turning the Adjust  
Rotate the Adjust knob to change values.  
knob.  
Depending on the defined weld process,  
Exit the Set Value mode by pressing the Setup  
either volts (MIG) or arc adjust [pulse, and Arc Control push buttons at the same time  
Accu-pulse, or RMD (optional)] can be or turning power source off and then back on  
changedin the top display. Wire speed can be again.  
Wire Feed Speed/Amps Display Push  
Button  
OM-210 540 Page 34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-2. Diagnostics  
The following error messages are shown on the  
upper and lower displays to indicate specific errors.  
Explanations are in the text below:  
ERR  
ERR  
ERR  
WFS  
ERR  
ERR  
ERR  
TACH  
MOTR  
STRT  
STOP  
FLOW  
Indicates a  
tachometer error.  
Indicates a motor  
error.  
Indicates a wire  
feed speed error.  
Indicates an arc  
start error.  
Indicates an arc  
stop error.  
Indicates a gas  
flow error.  
ERR  
ERR  
GND  
ERR  
ERR  
ERR  
ERR  
ARC  
COOL  
STUK  
TEMP  
LINE  
Indicates a coolant  
flow error.  
Indicates a ground  
current error.  
Indicates a wire  
stuck error.  
Indicates a  
temperature error.  
Indicates a line  
error.  
Indicates an arc  
error.  
ERR TACH  
ERR STOP  
ERR STUK  
• The stuck error occurs if the welding wire  
sticks to the workpiece at the end of a weld.  
May be caused by poor weld conditions.  
The error may be cleared by cutting wire  
from workpiece, and pressing the Jog/  
Purge button.  
• Tach error for Tach A occurs 2 seconds  
after the loss of tachometer feedback. The  
motor speed is regulated through the  
monitoring of voltage and current. Press  
Jog/Purge button to clear error.  
• The stop error occurs as result of  
obstructions in the wire feed system or a  
faulty wire drive system. Check wire feed  
and wire drive systems. Press Jog/Purge  
button to clear error.  
• Tach error for Tach B occurs 2 seconds  
after the loss of tachometer feedback. The  
motor speed is regulated through the  
monitoring of voltage and current. Press  
Jog/Purge button to clear error.  
ERR TEMP  
ERR FLOW  
• The temperature error indicates welding  
power source has overheated and  
shutdown. The error may be cleared by  
allowingunit to cool down, and pressing the  
Jog/Purge button. If problem persists,  
check fan motors and thermistors for proper  
operation. If unit is not overheated, check in-  
put line voltage. If input line voltage is okay,  
contact nearest factory authorized Service  
Agent.  
• The flow error indicates no gas flow to the  
gun. The error may be reset by  
reestablishinggas flow to the gun, and then  
pressing the Jog/Purge button.  
ERR MOTR  
• The motor error indicates that the motor  
has been drawing too much current for too  
long. To remedy this, reduce the wire feed  
speed or the wire feeder torque load/duty  
cycle. Press Jog/Purge button to clear error.  
ERR COOL  
• The cool error indicates no coolant flow in  
water flow switch option. The error may be  
ERR WFS  
reset by reestablishing coolant flow to the ERR LINE  
gun, and then pressing the Jog/Purge  
button.  
• The wire feed speed error indicates actual  
wire feed speed does not match wire feed  
speed command. Press Jog/Purge button  
to clear error.  
• The line error indicates input power is  
outside of unit operating range. Check and  
correct input power. Press Jog/Purge  
button to clear error.  
ERR GND  
ERR STRT  
ERR ARC  
• The ground current error occurs if weld  
• The start error, when enabled, occurs if the  
trigger is held longer than three seconds  
without an arc start. The error may be  
cleared by releasing the trigger, and  
pressing the Jog/Purge button.  
current is detected in the earth ground • The arc error indicates an arc outage  
connection. May be caused by a conductor  
making contact with unit chassis. Check  
and repair feeder weld connections. Turn  
power off and back on to clear error.  
occurred possibly from a wire feeder error  
or power source error. Check wire feeder  
and power source. Press Jog/Purge button  
to clear error.  
OM-210 540 Page 35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-2. Diagnostics (Continued)  
WELD  
WAIT  
MOTR  
COM  
PLS  
LOW  
WFS  
ROBT  
E
WAIT  
MEM  
STOP  
Indicates a UIM  
communication error.  
Indicates a CRC  
robot memory error. emergency stop error.  
Indicates an  
Indicates a weld  
cycle wait error.  
Indicates a motor  
communication error.  
Indicates a low WFS  
command error.  
RMD  
OVER  
UNIT  
OVER  
CRNT  
DONE  
AVG  
COMM  
Indicates RMD  
demo is done.  
Indicates an over  
average current error. PCM bus error.  
Indicates a CRC  
Indicates an  
overcurrent error.  
WELD WAIT  
ROBT MEM  
UNIT COMM  
• The unit communication error indicates  
the data bus on the PCM board is not  
functioning properly. Press Jog/Purge  
button to clear error.  
• The weld wait error indicates unit was not  
ready for a weld sequence. Press Jog/  
Purge button to clear error.  
• The robot memory error indicates robot  
lost memory data. Press Jog/Purge button  
to clear error.  
MOTR COM  
E STOP  
OVER CRNT  
• The motor communication error indi-  
cates motor board lost data communica-  
tions. Press Jog/Purge button to clear error.  
If condition persists, contact nearest factory  
authorized service agent.  
• The emergency stop error occurs if the  
user presses an emergency stop button.  
Reset the emergency stop button and press  
Jog/Purge button to clear error. Only applies  
to units equipped with E stop option.  
• The over current error indicates welding  
power source primary current of the inverter  
is too high. Turn welding power source off  
and disconnect unit for servicing.  
Attempting to reset the display to  
continue welding may further damage  
PLS WAIT  
RMD DONE  
internal components.  
A
complete  
• The uim communication error indicates  
prepower check of the unit is needed  
including resistance measurements of R1  
and R8 resistors on welding power source  
Interconnect board. Resistors should  
measure 30K ohms. Visually inspect  
electrolytic capacitors C1 and C2 for any  
possible damage. In the event of an over  
voltage condition, R1 and R8 could open  
potentially causing an imbalance in the  
power circuit. This condition would create  
excessive current in the inverter primary  
transformer and result in the OVER CRNT  
error.  
• The RMD done message indicates the  
RMD demo is completed. Pressing  
Jog/Purge button will change the screen to  
CYCL PWR on the display. Turn unit power  
off and back on again.  
user  
interface  
board  
lost  
data  
communications. Press Jog/Purge button  
to clear error. If condition persists, contact  
nearest factory authorized service agent.  
LOW WFS  
OVER AVG  
• The low wire feed speed error indicates  
actual wire feed speed is lower than wire • The over average error indicates that  
feed speed command. Check for  
obstructions in the wire feed system or a  
faulty wire drive system. Press Jog/Purge  
button to clear error.  
current is outside the average range for the  
set program parameters. Check and correct  
program parameters. Press Jog/Purge  
button to clear error.  
OM-210 540 Page 36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
7-2. Diagnostics (Continued)  
REL  
TRIG  
ERR  
TRIG  
STUK  
UNKN  
Indicates a contactor Indicates a trigger  
Indicates an  
unknown error.  
on error.  
closed error.  
REL TRIG  
ERR UNKN  
• The release trigger error indicates the  
user held the gun trigger after an E stop was  
reset causing the contactor to remain on.  
Press Jog/Purge button to clear error.  
• The unknown error indicates an error was  
sent from the PCM board to the UIM, but  
error condition is unknown. Make sure  
welding power source is isolated from the  
welding fixture. Press Jog/Purge button to  
clear error.  
TRIG STUK  
• The trigger stuck error indicates the user  
held the gun trigger during power up.  
Release trigger and turn power off and back  
on.  
OM-210 540 Page 37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
7-3. Removing Cover and Measuring Input Capacitor Voltage  
Turn Off welding power source, and  
disconnect input power.  
!
900 Volts dc can be present on the capacitor bus and  
significant DC voltage can remain on capacitors  
after unit is Off. Always check the voltage on both  
inverter assemblies as shown to be sure the input  
capacitorshave discharged before working on unit.  
Remove cover  
1
Power Interconnect Board  
PC2  
Tools Needed:  
2
Voltmeter  
5/16 in  
Measure the dc voltage across the  
+ bus terminal and − bus terminal on  
PC2 as shown until voltage drops to  
near 0 (zero) volts. Measure input  
capacitor voltage on both inverter  
assemblies before proceeding.  
3
Typical Bleeder Resistor  
An example of a typical bleeder  
resistor is shown on this page.  
Proceed with job inside unit.  
Reinstall cover when finished.  
1
2
+ lead to left bus terminal, − lead to right bus terminal  
1
2
3
Typical Bleeder Resistor  
+ lead to left bus terminal, − lead to right bus terminal  
25 to 1000 ohm, 5  
watt resistor  
#16 AWG 1000 volts dc  
insulation rating, approx  
3 in (76 mm) leads  
802 985 / Ref. 803 250-C  
OM-210 540 Page 38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-4. Process Control Module PC4 Diagnostic LED’s  
1
Process Control Module PC4  
Diagnostic LED’s are visible inside unit,  
located on PC4 mounted on the top tray.  
Refer to Section 7-5 for information on  
diagnostic LED’s.  
1
Reinstall cover after checking diagnostic  
LED’s.  
LED1  
LED2  
LED3  
LED4  
216 956-A / Ref. 803 250-C  
7-5. Diagnostic LED’s On Process Control Module PC4  
LED  
Status  
Diagnosis  
1
On  
Off  
On  
Off  
On  
Off  
Indicates −25 volts dc is present on process control module PC4  
Indicates −25 volts dc is not present on process control module PC4  
Indicates +25 volts dc is present on process control module PC4  
Indicates +25 volts dc is not present on process control module PC4  
See Network Status Table in Section 7-12  
2
3,4  
See Network Status Table in Section 7-12  
OM-210 540 Page 39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-6. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings  
1
Wire Feed Module PC6  
2
Diagnostic LED’s are visible inside  
unit, located on PC6 mounted on  
the top tray assembly.  
Refer to Section 7-7 for information  
on diagnostic LED’s.  
Reinstall top cover after checking  
diagnostic LED’s.  
1
LED1 LED2  
2
Dip Switch S1  
Dip switches are used to identify  
each circuit board on the internal  
network. Dip switch settings are  
different for each circuit board. For  
proper operation, do not change dip  
settings from those shown.  
LED3  
LED4  
217 333-B / 803 251-B  
7-7. Diagnostic LED’s On Wire Feed Module PC6  
LED  
Status  
Diagnosis  
1
On  
Off  
On  
Off  
On  
Off  
Indicates +15 volts dc is present on wire feed module PC6  
Indicates +15 volts dc is not present on wire feed module PC6  
Indicates +5 volts dc is present on wire feed module PC6  
Indicates +5 volts dc is not present on wire feed module PC6  
See Network Status Table in Section 7-12  
2
3,4  
See Network Status Table in Section 7-12  
OM-210 540 Page 40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-8. User Interface Module PC7 Diagnostic LED’s  
LED1  
LED2  
2
3
1
218 559-A / 803 251-B  
1
User Interface Module PC7  
Reinstall cover after checking diagnostic  
LED’s.  
Dip switches are used to identify each  
circuit board on the internal network. Dip  
switch settings are different for each circuit  
board. For proper operation, do not change  
dip settings from those shown.  
Diagnostic LED’s are visible inside unit,  
located on PC7 mounted behind the front  
panel.  
2
3
Dip Switch S1  
Dip Switch S2  
Refer to Section 7-9 for information on  
diagnostic LED’s.  
7-9. Diagnostic LED’s On User Interface Module PC7  
LED  
Status  
Diagnosis  
1, 2  
On  
See Network Status Table in Section 7-12  
See Network Status Table in Section 7-12  
Off  
OM-210 540 Page 41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-10. Automation Interface Module PC9 Diagnostic LED’s  
1
LED11  
LED13 LED25  
LED28  
LED27  
LED12  
LED14  
LED31  
LED30  
LED1  
LED2  
LED3  
LED4  
2
LED5  
LED6  
LED7  
LED8  
LED9  
LED10  
LED32  
LED33  
LED15  
LED20 LED19 LED18 LED16  
LED17  
LED21 LED22 LED23 LED24 LED26 LED29  
216 958-A / Ref. 803 250-C  
1
AutomationInterface Module PC9  
Reinstall cover after checking diagnostic  
LED’s.  
Dip switches are used to identify each  
circuit board on the internal network. Dip  
switch settings are different for each circuit  
board. For proper operation, do not change  
dip settings from those shown.  
Diagnostic LED’s are visible inside unit,  
located on PC9 mounted on left side.  
2
Dip Switch S4  
Refer to Section 7-9 for information on  
diagnostic LED’s.  
OM-210 540 Page 42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-11. Diagnostic LED’s On Automation Interface Module PC9  
LED  
Status  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
Diagnosis  
1
Input signal On from robot for jog advance  
Input signal Off from robot for no jog advance  
2
Input signal On from robot to energize contactor  
Input signal Off from robot to not energize contactor  
Input signal On remote program A selected  
Input signal Off remote program A not selected  
Input signal On remote program C selected  
Input signal Off remote program C not selected  
Input signal On from E-stop board PC12 for no emergency stop  
Input signal Off from E-stop board PC12 acknowledges E-stop is On from robot  
Spare 1 not assigned  
3
4
5
6
Spare 1 not assigned  
7
Input signal On Autoset-C selected  
Input signal Off Autoset-C not selected  
8
Input signal On Autoset-B selected  
Input signal Off Autoset-B not selected  
9
Input signal On Remote Jog on from peripheral plug  
Input signal Off Remote Jog off from peripheral plug  
Input signal On Remote Purge on from peripheral plug  
Input signal Off Remote Purge off from peripheral plug  
Input signal On from robot for jog retract  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
23  
Input signal Off from robot for no jog retract  
Input signal On from robot for purge  
Input signal Off from robot for no purge  
Input signal On remote program B selected  
Input signal Off remote program B not selected  
Input signal On Touch Sensor on from robot or peripheral plug  
Input signal Off Touch Sensor off from robot or peripheral plug  
Spare 0 not assigned  
Spare 0 not assigned  
Spare 2 not assigned  
Spare 2 not assigned  
Input signal On Autoset-A selected  
Input signal Off Autoset-A not selected  
Input signal On Autoset-D selected  
Input signal Off Autoset-D not selected  
Input signal On Remote Retract on from peripheral plug  
Input signal Off Remote Retract off from peripheral plug  
Input signal On Remote Water Flow on from peripheral plug  
Input signal Off Remote Water Flow off from peripheral plug  
Input signal On from robot for no emergency stop  
Input signal Off from robot for emergency stop  
Input signal On from relay K3 for welding power source ready and no detected errors present  
Input signal Off from relay K3 for welding power source not ready, detected errors are present, or unit is  
in operating mode preventing the weld ready signal from being enabled  
OM-210 540 Page 43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
LED  
Status  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
Diagnosis  
Input signal On from relay K4 to indicated wire stuck in weld joint  
Input signal Off from relay K4 to indicate wire is not stuck in weld joint  
Indicates +5 volts dc is present on automation module PC9  
Indicates +5 volts dc is not present on automation module PC9  
Input signal on from relay K5 for flow (shielding gas or coolant) present  
Input signal off from relay K5 for flow (shielding gas or coolant) not present  
Indicates −15 volts dc is present on automation interface module PC9  
Indicates −15 volts dc is not present on automation interface module PC9  
Indicates +15 volts dc is present on automation interface module PC9  
Indicates +15 volts dc is not present on automation interface module PC9  
Input signal on from relay K6 for arc detected  
24  
25  
26  
27  
28  
29  
Input signal off from relay K6 for no arc detected  
30, 31  
32  
See Network Status Table in Section 7-12  
See Network Status Table in Section 7-12  
Input signal on for aux. relay energized  
Input signal off for aux. relay energized  
33  
Input signal on touch sensor touch detected  
Input signal off touch sensor touch not detected  
OM-210 540 Page 44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
7-12. Network And Module Status LED’s  
A. Network Status LED’s  
The following are network status LED’s:  
LED1 on the UIM circuit board  
LED4 on the WFM and PCM circuit boards  
LED30 on the AIM circuit board.  
Status  
Diagnosis  
Off  
Green  
The circuit board is not on-line with the network or there is no power applied to the circuit board.  
The circuit board is operating normally and the on-line connection is made with the network.  
The circuit board is waiting for an on-line connection to be made with the network.  
Flashing Green  
Red  
The circuit board has encountered a communication link failure with the network. Check DeviceNet cable connections. Verify  
dip switch positions according to Sections 1-2 and 1-3. Replace circuit board if necessary.  
B. Module Status LED’s  
The following are module status LED’s:  
LED2 on the UIM circuit board  
LED3 on the WFM and PCM circuit boards  
LED31 on the AIM circuit board.  
Status  
Diagnosis  
Off  
Green  
There is no power applied to the circuit board or the board software is not executing its functions.  
The circuit board is operating normally.  
Flashing Red  
Red  
The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.  
The circuit board has encountered an unrecoverable fault.  
OM-210 540 Page 45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
7-13. Troubleshooting  
Trouble  
Remedy  
No weld output; completely inoperative Place line disconnect in On position (see Section 3-13).  
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-13).  
Check for proper input power connections (see Section 3-13).  
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.  
error displayed.  
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 3-9).  
errors displayed.  
Check that proper program for wire size, process, and shielding gas is loaded.  
Clean and tighten all weld connections.  
No 115 volts AC at the duplex receptacle. Reset supplementary protector CB1 (see Section 3-7).  
Wire does not feed.  
Check supplementary protector CB2 and reset if necessary (see Section 3-7).  
Check motor control cable connections.  
Wire feeds erratically.  
Readjust hub tension.  
Readjust drive roll pressure.  
Clean or replace dirty or worn drive rolls.  
Remove weld spatter around the nozzle opening.  
Replace contact tip or liner. See gun Owner’s Manual.  
Check motor control cable connections.  
Wire feeds as soon as power is supplied. Check gun trigger. See gun Owner’s Manual.  
Wire stubbing on low end using a Increase output setting of the power source.  
constant current power source.  
Check voltage sense lead connection, clean and tighten if necessary.  
Gas does not flow or does not stop flow- Check gas valve and flow meter.  
ing; wire feeds.  
Wire burns back to gun contact tip when Check to be sure that volt sense lead is connected to the work.  
using electrode negative (straight  
polarity) process.  
OM-210 540 Page 46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Notes  
OM-210 540 Page 47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8 − ELECTRICAL DIAGRAMS  
Figure 8-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)  
OM-210 540 Page 48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
207 903-G (Part 1 Of 2)  
OM-210 540 Page 49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Figure 8-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)  
OM-210 540 Page 50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
207 903-G (Part 2 Of 2)  
OM-210 540 Page 51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Figure 8-3. Circuit Diagram For 72 Pin Robot Interface  
OM-210 540 Page 52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
219 266-C  
OM-210 540 Page 53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Figure 8-4. Circuit Diagram For Peripheral/Motor Interface  
OM-210 540 Page 54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
219 267-B  
OM-210 540 Page 55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9 − PARTS LIST  
. Hardware is common and  
not available unless listed.  
1
2
3
4 − Fig 9-3  
5 − Fig 9-2  
7 − Fig 9-4  
6
8
17  
19  
5
18  
10  
18  
16 − Fig 9-5  
11  
8
12  
15  
9
13  
14  
15  
Ref. 803 247-D  
Figure 9-1. Main Assembly  
OM-210 540 Page 56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Figure 9-1. Main Assembly  
Quantity  
. . . 1 . . . . . T2 . . . . . . . 212543 . . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . . 210492 . . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . . 210481 . . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . . . . . . . . . . . . . . Fig 9-3 . . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . IM1, IM2 . . . . 222959 . . . MODULE, inverter assy (300A) (Fig 9-2) . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 6 . . . . . . . . . . . . . . . . 198961 . . . Panel, Module Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . . . . . . . . . . . . . Fig 9-4 . . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . . 227793 . . . Panel, Side W/Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 9 . . . . . . . . . . . . . . . . 210482 . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . W1 . . . . . . . 180270 . . . Contactor, DEF PRP 40A 3P 24VAC Coil W/Boxlug . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . . . . . . . . . . . . . 213386 . . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . HD2 . . . . . . 182918 . . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . . 1  
. . . 13 . . . . . . . . . . . . . . . . 198951 . . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . . 148025 . . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . . . . 213372 . . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 16 . . . . . . . . . . . . . . . . . Fig 9-5 . . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 227855 . . . Kit, Connectors W/Washer For Power Cables (Includes) . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . . 010467 . . . . Connector, Clamp Cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . . 225840 . . . . Washer, Reducer 1.25 in − 0.75 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 19 . . . . . . . . . . . . . . . . 010916 . . . . Connector, Clamp Cable 0.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
*Recommended Spare Parts.  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
14  
. Hardware is common and  
15  
not available unless listed.  
2
1
3
4
5
6
7
12  
11  
8
13  
9
33  
34  
10  
35  
17  
6
16  
18  
7
19  
32  
31  
20  
21  
30  
23  
24  
29  
25  
23  
27  
36  
13  
28  
26  
22  
23  
38  
37  
802 955-A  
Figure 9-2. Windtunnel Assembly LH And RH  
OM-210 540 Page 57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 9-2. Windtunnel Assembly LH And RH (Fig 9-1 Item 6)  
. . . 1 . . . . . . . . . . . . . . . . 214597 . . . Windtunnel, LH w/Components (including). . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . . 196351 . . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . L1 . . . . . . . 213940 . . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . . . . . . . . . . . . . 214519 . . . . Insulator, Heat Sink Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . R3, C4 . . . . . 233052 . . . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . . . . . . . . . . . 199840 . . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 7 . . . D1, D2 . . . . . 201531 . . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 8 . . . . . . . . . . . . . . . . 196347 . . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . . 196349 . . . . Spacer, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 10 . . . . . T1 . . . . . . . 203408 . . . . Xfmr, HF Litz/Litz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . . Z1 . . . . . . . 220496 . . . . Output Inductor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . . . . . . . . . . . . . 170647 . . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . 2  
. . . 13 . . . . . . . . . . . . . . . . 179276 . . . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . 4  
. . . 14 . . . . . . . . . . . . . . . . 196355 . . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
. . . 15 . . . . . . . . . . . . . . . . 010546 . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . . . . 222958 . . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . . 196332 . . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . . 030170 . . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . 2  
. . . 19 . . . . . . . . . . . . . . . . 196259 . . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 115092 . . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 115091 . . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . CT1 . . . . . . 196231 . . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . . . . . 201695 . . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 21 . . . C1, C2 . . . . . 226081 . . . . Capacitor,Elctlt 2400 Uf 500 Vdc Can 2.50 Dia . . . . . . . . . . . . . . . . . 2  
. . . 22 . . . . . . . . . . . . . . . . 210507 . . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 23 . . . . . . . . . . . . . . . . 217625 . . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 RT1,RT2.RT3 . . 214015 . . . . Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead . . . . . . . . . . . . 3  
. . . 25 . . . . PC2 . . . . . . 222661 . . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . C3 . . . . . . . 196143 . . . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . . 1  
. . . 27 . . . . . . . . . . . . . . . . 196378 . . . . Bracket, Mtg Current Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 28 . . . . HD1 . . . . . . 182918 . . . . Transducer, Current 400A Module Supply V +/− 15v . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 196384 . . . . Cable, Transducer 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . R1, R2 . . . . . 196343 . . . . Resistors, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 196840 . . . . Insulator, Resistors/Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 30 . . . . . . . . . . . . . . . . 109056 . . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . . 1  
. . . 31 . . . . . . . . . . . . . . . . 196514 . . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 32 . . . . . . . . . . . . . . . . 196512 . . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 33 . . . . . . . . . . . . . . . . 196330 . . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 34 . . . . . L2 . . . . . . . 196345 . . . . Coil, Inductor (Pre−regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 35 . . . . . . . . . . . . . . . . 196588 . . . . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 196365 . . . . Plugs, w/Leads (Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 199136 . . . . Plugs, w/Leads (PC2 To PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 36 . . . . PC1 . . . . . . 214523 . . . Circuit Card Assy, Control (Inverter 300A) . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 37 . . . . . . . . . . . . . . . . 204846 . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 38 . . . . . . . . . . . . . . . . 083147 . . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . 4  
*Recommended Spare Parts.  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-210 540 Page 58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
1
. Hardware is common and  
not available unless listed.  
2
3
4
5
6
11  
10  
7
9
8
802 916-B  
Figure 9-3. Top Tray Assembly  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 9-3. Top Tray Assembly (Fig 9-1 Item 4)  
. . . 1 . . . . PC12 . . . . . . 209676 . . . Circuit Card Assy, E−stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . PC3 . . . . . . 231928 . . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . . 210490 . . . Bracket, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . . . . . . . . . . . . . 134201 . . . Stand−Off, PC Card .312/.375/Post&Lock .43 . . . . . . . . . . . . . . . . . . . . . 4  
. . . 5 . . . . . . . . . . . . . . . . 083147 . . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . 24  
. . . 6 . . . . PC4 . . . . . . 221277 . . . Process Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . . . . . . . . . . . . 170647 . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . . 210491 . . . Tray, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . . 223439 . . . Insulator, Circuit Card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . . 198122 . . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . . 1  
. . . 11 . . . . PC6 . . . . . . 221280 . . . Wire Feed Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
*Recommended Spare Parts.  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-210 540 Page 59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
. Hardware is common and  
9
not available unless listed.  
8
5
7
6
4
3
2
1
10  
15  
11  
12  
14  
13  
803 248-D  
Figure 9-4. Rear Panel Assembly  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 9-4. Rear Panel Assembly (Fig 9-1 Item 8)  
. . . 1 . . . . PC9 . . . . . . 221279 . . . Automation Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . . 199297 . . . Stand-off, no 6-32 & no 8-32 x 2.50 lg .312 hex alm/m . . . . . . . . . . . . . 4  
. . . 3 . . . . PC10 . . . . . . 214855 . . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . . . . . . . . . . . . . 199295 . . . Stand-off, no 8-32 x .500 lg .312 hex al m&f . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 5 . . . . . . . . . . . . . . . . 217297 . . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . . . . . . . . . . . 207894 . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . . . . . . . . . . . . 210358 . . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . . 210505 . . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . . 201058 . . . Connector, Rect 72 Pin Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . . 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . CB1 . . . . . . 083432 . . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . . 1  
. . . 12 . . . . CB2 . . . . . . 093995 . . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . . 1  
. . . 13 . . . . PC11 . . . . . . 216213 . . . Circuit Card Assy, Motor Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . RC2 . . . . . . 604176 . . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . . . . 216596 . . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
*Recommended Spare Parts.  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-210 540 Page 60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
. Hardware is common and  
not available unless listed.  
4
2
1
7
6
5
26  
11  
10  
3
24  
25  
23  
9
10  
8
22  
17  
16  
11  
10  
12  
15  
13  
21  
18  
14  
12  
19  
20  
20  
Ref. 803 249-C  
Figure 9-5. Front Panel Assembly  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 9-5. Front Panel Assembly (Fig 9-1 Item 14)  
. . . 1 . . . . . S1 . . . . . . . 207456 . . . Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . . 207895 . . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . . 179851 . . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . 1  
. . . 4 . . . . . . . . . . . . . . . . 204393 . . . Panel, PC Card Front (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 204394 . . . . Panel, PC Card Switch/Overlay (including) . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . . . . . . . . . . . . . 200410 . . . . . . Nameplate, Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . PC20 . . . . . . 227879 . . . . . . Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . PC7 . . . . . . 221278 . . . . User Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 200416 . . . . . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . . 199376 . . . . . . Circuit Card Assy, User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . FM . . . . . . . 196313 . . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . . 2  
. . . 9 . . . . PC13 . . . . . . 208071 . . . Circuit Card Assy,ISO/COMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . C6, C7, C8 . . . 206878 . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 11 . . . . . . . . . . . . . . . . 213102 . . . Choke, Common Mode w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . . . . 025248 . . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . 2  
. . . 13 . . . . . . . . . . . . . . . . 207897 . . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 14 . . . . . . . . . . . . . . . . 210866 . . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . RC5 . . . . . . 214664 . . . Receptacle, Common Mode Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-210 540 Page 61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 9-5. Front Panel Assembly (Fig 9-1 Item 14) (Continued)  
. . . 16 . . . . . . . . . . . . . . . . 216966 . . . Cover, Connector D-sub 9 pin Male w/Chain . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . . 216965 . . . Cover, Connector D-sub 9 skt Female w/Chain . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . . 219843 . . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . . . . 207896 . . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . . . . . 186621 . . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 21 PB1, PB2, PB3 . . 199443 . . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . . 3  
. . . 22 . . . . . . . . . . . . . . . . 207902 . . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . . . . . 210865 . . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . . . . . 207893 . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . . . . . 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . . . . . . . . . . . . 210358 . . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
*Recommended Spare Parts.  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-210 540 Page 62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
www.millerwelds.com or call 1-800-4-A-Miller  
www.MillerWelds.com  
Contact the Delivering Carrier to:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims, contact  
your distributor and/or equipment manufacturer’s  
Transportation Department.  
PRINTED IN USA  
© 2007 Miller Electric Mfg. Co.2007−01  
Download from Www.Somanuals.com. All Manuals Search And Download.  

NAD DVD Player T 514DVD User Manual
NEC Drill 0724 20 User Manual
NEC DVD Recorder NDH 81 NDH 161 User Manual
NEC Projector VT580 User Manual
NetComm Network Router NB504 User Manual
Nike Fitness Equipment + IPOD User Manual
Oricom Two Way Radio UHF050 User Manual
OWI Portable Speaker P8378P User Manual
Panasonic Digital Camera AW E560 User Manual
Panasonic Home Safety Product EY3794 User Manual