OM-228 873G 2008−10

Processes
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 DI

Visit our website at

File: Advanced Manufacturing Systems
www.MillerWelds.com/ams
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. Standard Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-7. Optional Tandem Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-8. Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-9. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-10. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-11. Devicenet Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-12. Motor Control Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-13. E-Stop Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-14. Tandem Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-15. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-16. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-17. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-18. 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. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 5 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
 TABLE OF CONTENTS

SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-3. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7-4. Process Control Module PC4 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-5. Diagnostic LED’s On Process Control Module PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-6. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-7. Diagnostic LED’s On Wire Feed Module PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-8. User Interface Module PC7 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-9. Diagnostic LED’s On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-10. Network And Module Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
WARRANTY
 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 This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex- SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text. bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Arc Welding Hazards

D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord for damage or bare wiring −
repair this unit. replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
During operation, keep everybody, especially children, away. D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill. D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks D Do not touch electrode if you are in contact with the work, ground,
or severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also D Do not touch electrode holders connected to two welding ma-
live when power is on. In semiautomatic or automatic wire welding, the chines at the same time since double open-circuit voltage will be
wire, wire reel, drive roll housing, and all metal parts touching the present.
welding wire are electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Wear dry, hole-free insulating gloves and body protection.
D Keep all panels and covers securely in place.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work D Clamp work cable with good metal-to-metal contact to workpiece
or ground. or worktable as near the weld as practical.
D Do not use AC output in damp areas, if movement is confined, or if D Insulate work clamp when not connected to workpiece to prevent
there is a danger of falling. contact with any metal object.
D Use AC output ONLY if required for the welding process. D Do not connect more than one electrode or work cable to any
D If AC output is required, use remote output control if present on single weld output terminal.
unit.
D Additional safety precautions are required when any of the follow-
SIGNIFICANT DC VOLTAGE exists in inverter-type
ing electrically hazardous conditions are present: in damp welding power sources after removal of input
locations or while wearing wet clothing; on metal structures such power.
as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt- HOT PARTS can cause severe burns.
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone! D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or D Allow cooling period before working on gun or
servicing this equipment. Lockout/tagout input power according to torch.
OSHA 29 CFR 1910.147 (see Safety Standards). D To handle hot parts, use proper tools and/or
D Properly install and ground this equipment according to its wear heavy, insulated welding gloves and
Owner’s Manual and national, state, and local codes. clothing to prevent burns.

OM-228 873 Page 1

 D Do not use welder to thaw frozen pipes.
FUMES AND GASES can be hazardous.
D 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 D Wear oil-free protective garments such as leather gloves, heavy
health. shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
D Keep your head out of the fumes. Do not breathe the fumes. from your person before doing any welding.
D If inside, ventilate the area and/or use local forced ventilation at the D After completion of work, inspect area to ensure it is free of sparks,
arc to remove welding fumes and gases. glowing embers, and flames.
D If ventilation is poor, wear an approved air-supplied respirator. D Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables, D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
coatings, cleaners, and degreasers. 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-
FLYING METAL or DIRT can injure eyes.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
ing air is safe.
they can throw off slag.
D Do not weld in locations near degreasing, cleaning, or spraying op-
D Wear approved safety glasses with side
erations. The heat and rays of the arc can react with vapors to form
shields even under your welding helmet.
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
BUILDUP OF GAS can injure or kill.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements D Shut off shielding gas supply when not in use.
can give off toxic fumes if welded. D Always ventilate confined spaces or use
approved air-supplied respirator.

ARC RAYS can burn eyes and skin.

MAGNETIC FIELDS can affect Implanted
Arc rays from the welding process produce intense Medical Devices.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the D Wearers of Pacemakers and other Implanted
weld.
Medical Devices should keep away.
D Wear an approved welding helmet fitted with a proper shade of fil- D Implanted Medical Device wearers should consult their doctor
ter lenses to protect your face and eyes when welding or watching and the device manufacturer before going near arc welding, spot
(see ANSI Z49.1 and Z87.1 listed in Safety Standards). welding, gouging, plasma arc cutting, or induction heating
D Wear approved safety glasses with side shields under your operations.
helmet.
D Use protective screens or barriers to protect others from flash, NOISE can damage hearing.
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant mate- Noise from some processes or equipment can
rial (leather, heavy cotton, or wool) and foot protection. damage hearing.
D Wear approved ear protection if noise level is
WELDING can cause fire or explosion. high.

Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.

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 Shielding gas cylinders contain gas under high
burns. Accidental contact of electrode to metal objects can cause pressure. If damaged, a cylinder can explode. Since
sparks, explosion, overheating, or fire. Check and be sure the area is gas cylinders are normally part of the welding
safe before doing any welding. process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechani-
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
cal shocks, physical damage, slag, open flames, sparks, and arcs.
this is not possible, tightly cover them with approved covers.
D Install cylinders in an upright position by securing to a stationary
D Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
D Protect yourself and others from flying sparks and hot metal. D Keep cylinders away from any welding or other electrical circuits.
D Be alert that welding sparks and hot materials from welding can D Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas. D Never allow a welding electrode to touch any cylinder.
D Watch for fire, and keep a fire extinguisher nearby. D Never weld on a pressurized cylinder − explosion will result.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can D Use only correct shielding gas cylinders, regulators, hoses, and fit-
cause fire on the hidden side. tings designed for the specific application; maintain them and
D Do not weld on closed containers such as tanks, drums, or pipes, associated parts in good condition.
unless they are properly prepared according to AWS F4.1 (see D Turn face away from valve outlet when opening cylinder valve.
Safety Standards). D Keep protective cap in place over valve except when cylinder is in
D Do not weld where the atmosphere may contain flammable dust, use or connected for use.
gas, or liquid vapors (such as gasoline). D Use the right equipment, correct procedures, and sufficient num-
D Connect work cable to the work as close to the welding area as ber of persons to lift and move cylinders.
practical to prevent welding current from traveling long, possibly D Read and follow instructions on compressed gas cylinders,
unknown paths and causing electric shock, sparks, and fire associated equipment, and Compressed Gas Association (CGA)
hazards. publication P-1 listed in Safety Standards.
OM-228 873 Page 2
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 D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit. guards for maintenance as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
FALLING UNIT can cause injury. finished and before reconnecting input power.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories. READ INSTRUCTIONS.
D Use equipment of adequate capacity to lift and
support unit. D Read Owner’s Manual before using or servic-
D If using lift forks to move unit, be sure forks are ing unit.
long enough to extend beyond opposite side of D Use only genuine replacement parts from the
unit. manufacturer.

OVERUSE can cause OVERHEATING

H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D High-frequency (H.F.) can interfere with radio
D Reduce current or reduce duty cycle before navigation, safety services, computers, and
starting to weld again. communications equipment.
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 The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
D Wear a face shield to protect eyes and face. tion.
D Shape tungsten electrode only on grinder with D If notified by the FCC about interference, stop using the
proper guards in a safe location wearing proper equipment at once.
face, hand, and body protection. D Have the installation regularly checked and maintained.
D Sparks can cause fires — keep flammables away. D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
STATIC (ESD) can damage PC boards. minimize the possibility of interference.

D Put on grounded wrist strap BEFORE handling

boards or parts. ARC WELDING can cause interference.
D 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
MOVING PARTS can cause injury. such as robots.
D Be sure all equipment in the welding area is
D Keep away from moving parts.
electromagnetically compatible.
D Keep away from pinch points such as drive
rolls. D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
WELDING WIRE can cause injury. tronic equipment.
D Be sure this welding machine is installed and grounded
D Do not press gun trigger until instructed to do
according to this manual.
so.
D If interference still occurs, the user must take extra measures
D Do not point gun toward any part of the body,
such as moving the welding machine, using shielded cables,
other people, or any metal when threading
using line filters, or shielding the work area.
welding wire.

OM-228 873 Page 3

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 Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
from Global Engineering Documents (phone: 1-877-413-5184, website: 416-747-4044, website: www.csa-international.org).
www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec-
Recommended Safe Practices for the Preparation for Welding and Cut- tion, ANSI Standard Z87.1, from American National Standards Institute,
ting of Containers and Piping, American Welding Society Standard 25 West 43rd Street, New York, NY 10036–8002 (phone:
AWS F4.1, from Global Engineering Documents (phone: 212-642-4900, website: www.ansi.org).
1-877-413-5184, website: www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
National Electrical Code, NFPA Standard 70, from National Fire Protec- Work, NFPA Standard 51B, from National Fire Protection Association,
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
617-770-3000, website: www.nfpa.org and www. sparky.org). site: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
from Compressed Gas Association, 4221 Walney Road, 5th Floor, and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Code for Safety in Welding and Cutting, CSA Standard W117.2, from (phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Canadian Standards Association, Standards Sales, 5060 Mississauga, Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them, or using a
Electric And Magnetic Fields cable cover.

Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
5. Connect work clamp to workpiece as close to the weld as possi-
frequency electric and magnetic fields is a human-health hazard.”
ble.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Implanted Medical Devices:
may wish to minimize your exposure to electromagnetic fields when Implanted Medical Device wearers should consult their doctor and the
welding or cutting. device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
To reduce magnetic fields in the workplace, use the following If cleared by your doctor, then following the above procedures is recom-
procedures: mended.

OM-228 873 Page 4

 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 Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures afférant pour les actions nécessaires afin d’éviter le danger.
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
Les symboles représentés ci-dessous sont utilisés dans ce ma- souder AC à tension à vide réduite. Dans la plupart des situations,
nuel pour attirer l’attention et identifier les dangers possibles. En l’utilisation d’un poste à souder DC à fil à tension constante est re-
présence de l’un de ces symboles, prendre garde et suivre les commandée. En outre, ne pas travailler seul !
instructions afférentes pour éviter tout risque. Les instructions
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
en matière de sécurité indiquées ci-dessous ne constituent
stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
qu’un sommaire des instructions de sécurité plus complètes
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
fournies dans les normes de sécurité énumérées dans la Sec-
mes de sécurité).
tion 2-5. Lire et observer toutes les normes de sécurité.
D Installer le poste correctement et le mettre à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
Seul un personnel qualifié est autorisé à installer, faire fonc- nationales, provinciales et locales.
tionner, entretenir et réparer cet appareil. D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
Pendant le fonctionnement, maintenir à distance toutes les raccordé à la borne de terre du sectionneur ou que la fiche du
personnes, notamment les enfants de l’appareil. cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
UNE DÉCHARGE ÉLECTRIQUE peut teur de mise à la terre approprié et contre-vérifier les connexions.
entraîner la mort. D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
Le contact d’organes électriques sous tension peut protégez−les contre les étincelles et les pièces métalliques
provoquer des accidents mortels ou des brûlures chaudes.
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la D Vérifier fréquemment le cordon d’alimentation afin de s’assurer
sortie. Le circuit d’alimentation et les circuits internes de la machine qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
sont également sous tension lorsque l’alimentation est sur Marche. Un fil à nu peut entraîner la mort.
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 D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
avec le fil sont sous tension électrique. Un équipement installé ou mis D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
à la terre de manière incorrecte ou impropre constitue un danger. sante ou mal épissés.
D Ne pas toucher aux pièces électriques sous tension. D Ne pas enrouler les câbles autour du corps.
D Porter des gants isolants et des vêtements de protection secs et D Si la pièce soudée doit être mise à la terre, le faire directement
sans trous. avec un câble distinct.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou D Ne pas toucher l’électrode quand on est en contact avec la pièce,
des tapis assez grands afin d’éviter tout contact physique avec la la terre ou une électrode provenant d’une autre machine.
pièce à couper ou le sol. D Ne pas toucher des porte électrodes connectés à deux machines
D Ne pas se servir de source électrique à courant électrique dans les en même temps à cause de la présence d’une tension à vide dou-
zones humides, dans les endroits confinés ou là où on risque de blée.
tomber. D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
D Se servir d’une source électrique à courant électrique UNIQUE- champ les pièces endommagées. Entretenir l’appareil conformé-
MENT si le procédé de soudage le demande. ment à ce manuel.
D Si l’utilisation d’une source électrique à courant électrique s’avère D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
nécessaire, se servir de la fonction de télécommande si l’appareil D S’assurer que tous les panneaux et couvercles sont correctement
en est équipé. en place.
D D’autres consignes de sécurité sont nécessaires dans les condi- D Fixer le câble de retour de façon à obtenir un bon contact métal-
tions suivantes : risques électriques dans un environnement métal avec la pièce à souder ou la table de travail, le plus près pos-
humide ou si l’on porte des vêtements mouillés ; sur des structures sible de la soudure.
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque D Isoler la pince de masse quand pas mis à la pièce pour éviter le
élevé de contact inévitable ou accidentel avec la pièce à souder ou contact avec tout objet métallique.
le sol. Dans ces conditions, utiliser les équipements suivants, D Ne pas raccorder plus d’une électrode ou plus d’un câble de
dans l’ordre indiqué : 1) un poste à souder DC à tension constante masse à une même borne de sortie de soudage.
OM-228 873 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in
les sources de soudage onduleur quand on a cendie ou une explosion.
coupé l’alimentation.
Le soudage effectué sur des conteneurs fermés tels
D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut
décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement. Des étincelles peuvent
indiquées dans la partie Entretien avant de toucher les pièces. être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
DES PIÈCES CHAUDES peuvent incendies et des brûlures. Le contact accidentel de l’électrode avec
provoquer des brûlures graves. des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
D Ne pas toucher à mains nues les parties
vérifier et s’assurer que l’endroit ne présente pas de danger.
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
D Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
soigneusement avec des protections homologués.
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures. D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent D Se protéger et d’autres personnes de la projection d’étincelles et
être dangereux. de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
Le soudage génère des fumées et des gaz. Leur facilement passer dans d’autres zones en traversant de petites
inhalation peut être dangereux pour votre santé. fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
D Eloigner votre tête des fumées. Ne pas respirer les fumées. proximité.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au D Le soudage effectué sur un plafond, plancher, paroi ou séparation
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs D Ne pas effectuer le soudage sur des conteneurs fermés tels que
approuvé. des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor-
D Lire et comprendre les spécifications de sécurité des matériaux mes de sécurité).
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais- D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
seurs. peurs inflammables (vapeur d’essence, par exemple).
D Travailler dans un espace fermé seulement s’il est bien ventilé ou D Brancher le câble de masse sur la pièce le plus près possible de la
en portant un respirateur à alimentation d’air. Demander toujours à zone de soudage pour éviter le transport du courant sur une
un surveillant dûment formé de se tenir à proximité. Des fumées et longue distance par des chemins inconnus éventuels en provo-
des gaz de soudage peuvent déplacer l’air et abaisser le niveau quant des risques d’électrocution, d’étincelles et d’incendie.
d’oxygène provoquant des blessures ou des accidents mortels. D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
S’assurer que l’air de respiration ne présente aucun danger. lées.
D Ne pas souder dans des endroits situés à proximité d’opérations D En cas de non utilisation, enlever la baguette d’électrode du porte-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et électrode ou couper le fil à la pointe de contact.
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
mer des gaz hautement toxiques et irritants. D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier revers, des chaussures hautes et un couvre chef.
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 D Avant de souder, retirer toute substance combustible de vos po-
bien ventilé, et en portant un respirateur à alimentation d’air. Les ches telles qu’un allumeur au butane ou des allumettes.
revêtements et tous les métaux renfermant ces éléments peuvent D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
dégager des fumées toxiques en cas de soudage. trace d’étincelles incandescentes ni de flammes.

LES RAYONS DE L’ARC peuvent D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
provoquer des brûlures dans les
yeux et sur la peau. D 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 intense D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
soudage. 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
D Porter des lunettes de sécurité avec écrans latéraux même sous SALETES peuvent provoquer des
votre casque. blessures dans les yeux.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
protéger les autres contre les rayonnements les éblouissements
fil de fer, et le meulage génèrent des étincelles et des particules
et les étincelles ; prévenir toute personne sur les lieux de ne pas
métalliques volantes. Pendant la période de refroidissement des
regarder l’arc.
soudures, elles risquent de projeter du laitier.
D Porter des vêtements confectionnés avec des matières résistan- D Porter des lunettes de sécurité avec écrans latéraux ou un écran
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de facial.
protection.
OM-228 873 Page 6
 D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
LES ACCUMULATIONS DE GAZ des chocs mécaniques, des dommages physiques, du laitier, des
risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs.
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas D Placer les bouteilles debout en les fixant dans un support station-
de non-utilisation. naire ou dans un porte-bouteilles pour les empêcher de tomber ou
D Veiller toujours à bien aérer les espaces confi- de se renverser.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux. D Ne jamais placer une torche de soudage sur une bouteille à gaz.

D Porteur de simulateur cardiaque ou autre im- D Une électrode de soudage ne doit jamais entrer en contact avec
plants médicaux, rester à distance. 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- D Ne jamais souder une bouteille pressurisée − risque d’explosion.
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
LE BRUIT peut endommager l’ouïe. les maintenir ainsi que les éléments associés en bon état.

Le bruit des processus et des équipements peut D Détourner votre visage du détendeur-régulateur lorsque vous
affecter l’ouïe. ouvrez la soupape de la bouteille.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé. D 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 D Utiliser les équipements corrects, les bonnes procédures et suffi-
si elles sont endommagées. 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- D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
gée, elle peut exploser. Du fait que les bouteilles de l’équipement connexe et le dépliant P-1 de la CGA (Compressed
gaz font normalement partie du procédé de sou- Gas Association) mentionné dans les principales normes de sécu-
dage, les manipuler avec précaution. rité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO- LES ÉTINCELLES VOLANTES ris-

SION. quent de provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou D Porter un écran facial pour protéger le visage et
à proximité de surfaces inflammables. les yeux.
D Ne pas installer l’appareil à proximité de pro- D Affûter l’électrode au tungstène uniquement à la
duits inflammables. meuleuse dotée de protecteurs. Cette manœuv-
D Ne pas surcharger l’installation électrique − s’assurer que re est à exécuter dans un endroit sûr lorsque l’on
l’alimentation est correctement dimensionnée et protégée avant porte l’équipement homologué de protection du
de mettre l’appareil en service. visage, des mains et du corps.
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 LES CHARGES ÉLECTROSTATI-
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire. QUES peuvent endommager les
D Utiliser un équipement de levage de capacité
circuits imprimés.
suffisante pour lever l’appareil. D Établir la connexion avec la barrette de terre
D En utilisant des fourches de levage pour déplacer l’unité, s’assu- avant de manipuler des cartes ou des pièces.
rer que les fourches sont suffisamment longues pour dépasser D Utiliser des pochettes et des boîtes antistati-
du côté opposé de l’appareil. ques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.

L’EMPLOI EXCESSIF peut SUR-

CHAUFFER L’ÉQUIPEMENT.
DES ORGANES MOBILES peuvent
D Prévoir une période de refroidissement ; re-
provoquer des blessures.
specter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche D Ne pas s’approcher des organes mobiles.
avant de poursuivre le soudage. D Ne pas s’approcher des points de coincement
D Ne pas obstruer les passages d’air du poste. tels que des rouleaux de commande.

OM-228 873 Page 7

 LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ-
provoquer des blessures. QUENCE (H.F.) risque de provoquer
D Ne pas appuyer sur la gâchette avant d’en des interférences.
avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut
D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe-
sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-
geant le fil de soudage. tion, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
DES ORGANES MOBILES peuvent D L’utilisateur est tenu de faire corriger rapidement par un électricien
provoquer des blessures. qualifié les interférences résultant de l’installation.
D S’abstenir de toucher des organes mobiles tels D Si le FCC signale des interférences, arrêter immédiatement l’ap-
que des ventilateurs. pareil.
D Maintenir fermés et verrouillés les portes, pan-
neaux, recouvrements et dispositifs de protec- LE SOUDAGE À L’ARC risque de
tion. provoquer des interférences.
D Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection D L’énergie électromagnétique risque de provo-
pour l’entretien. quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et l’é-
D Remettre les portes, panneaux, recouvrements ou dispositifs de quipement commandé par ordinateur tel que
protection quand l’entretien est terminé et avant de rebrancher
les robots.
l’alimentation électrique.
D Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
LIRE LES INSTRUCTIONS. D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
D Lisez le manuel d’instructions avant l’utilisation aussi bas que possible (ex. par terre).
ou la maintenance de l’appareil. D Veiller à souder à une distance de 100 mètres de tout équipe-
D N’utiliser que les pièces de rechange recom- ment électronique sensible.
mandées par le constructeur. D 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. D En cas d’interférences après avoir pris les mesures précéden-
D Maintenir soigneusement fermés les portes et les panneaux des tes, il incombe à l’utilisateur de prendre des mesures supplé-
sources de haute fréquence, maintenir les éclateurs à une distan- mentaires telles que le déplacement du poste, l’utilisation de câ-
ce correcte et utiliser une terre et un blindage pour réduire les bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
interférences éventuelles. teurs dans la zone de travail.

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- Les gaz d’échappement des moteurs contiennent des pro-
formations congénitales et, dans certains cas, des cancers. duits chimiques dont l’État de Californie reconnaît qu’ils
(Code de santé et de sécurité de Californie, chapitre 25249.5 provoquent des cancers et des malformations congénitales
et suivants) 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 Les gaz d’échappement des moteurs diesel et certains de
cancers et des malformations congénitales ou autres leurs composants sont reconnus par l’État de Californie com-
problèmes de procréation. Se laver les mains après manipu- me provoquant des cancers et des malformations
lation. congénitales ou autres problèmes de procréation.

OM-228 873 Page 8

2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org).
Internet : www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
Recommended Safe Practices for the Preparation for Welding and Cut- tion, ANSI Standard Z87.1, de American National Standards Institute,
ting of Containers and Piping, American Welding Society Standard 11 West 43rd Street, New York, NY 10036-8002 (téléphone :
AWS F4.1 de Global Engineering Documents (téléphone : 212-642-4900, site Internet : www.ansi.org).
1-877-413-5184, site Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
National Electrical Code, NFPA Standard 70, de National Fire Protec- Work, NFPA Standard 51B, de National Fire Protection Association,
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
617-770-3000, site Internet : www.nfpa.org). site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, OSHA, Occupational Safety and Health Standards for General Indus-
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
tilly, VA 20151 (téléphone : 703-788-2700, site Internet : and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
www.cganet.com). tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
Code for Safety in Welding and Cutting, CSA Standard W117.2, de ne de la région 5, Chicago, est 312-353-2220, site Internet :
Canadian Standards Association, 5060 Mississauga, Ontario, Canada www.osha.gov).

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des 1. Garder les câbles ensemble, les torsader, les scotcher, ou les
champs magnétiques et électriques. recouvrir d’une housse.
Le courant de soudage, pendant son passage dans les câbles de sou- 2. Disposer les câbles d’un côté et à distance de l’opérateur.
dage, causera des champs électromagnétiques. Il y a eu et il y a encore 3. Ne pas courber pas et ne pas entourer pas les câbles autour de
un certain souci à propos de tels champs. Cependant, après avoir exa- votre corps.
miné plus de 500 études qui ont été faites pendant une période de 4. Garder le poste de soudage et les câbles le plus loin possible de
recherche de 17 ans, un comité spécial ruban bleu du National vous.
Research Council a conclu : « L’accumulation de preuves, suivant le 5. Connecter la pince sur la pièce aussi près que possible de la
jugement du comité, n’a pas démontré que l’exposition aux champs
soudure.
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en En ce qui concerne les implants médicaux :
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait Les porteurs d’implants doivent d’abord consulter leur médecin avant
souhaitable de réduire votre exposition aux champs électromagnéti- de s’approcher des opérations de soudage à l’arc, de soudage par
ques pendant le soudage ou le coupage. points, de gougeage, du coupage plasma ou de chauffage par induc-
Pour réduire les champs magnétiques sur le poste de travail, appliquer tion. Si le médecin approuve, il est recommandé de suivre les
les procédures suivantes : procédures précédentes.

OM-228 873 Page 9

OM-228 873 Page 10
 SECTION 3 − INSTALLATION
. Appearance of actual unit may vary from unit shown in manual.
3-1. Specifications
Max
Rated Wire Feed Wire Open Amperes Input At Rated Load Output 60 Hz,
Input Voltage Three-Phase Input Input
Welding Speed Diameter Circuit
Power Range kVA KW
Output Range** Range Voltage 208 V 230 V 400V 460 V 575 V
DC

Three 450 A @ 10-44 Standard: .035-.062 in 80 67.0 59.0 34.0 29.0 23.0 23.8 22.9
Phase 44 V DC, 50-1400 (0.8-1.6 mm) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0.8*) (0.17*)
100% ipm
Duty (1.3-35.6
Cycle 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
A 22-1/2 in
(572 mm)
A 17-3/32 in (434 mm)

B 17-3/8 in (441 mm)

31 in
C 19-3/32 in (485 mm) (787 mm)

D 16-3/32 in (409 mm) C B

E 1/2 in (13 mm)

Weight
17-3/32 in
(434 mm)
163 lb (74 kg) Net
180 lb (82 kg) Ship
D
Ref. 803 244-B

OM-228 873 Page 11

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

Continuous Welding 6 Minutes Welding 4 Minutes Resting

Overheating

0 A/V

15
OR
Minutes Reduce Duty Cycle

duty1 4/95 − 220 485-A

3-4. Volt-Ampere Curves

CV MODE Volt-ampere curves show minimum
and maximum voltage and
80 amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
70
. This volt-ampere curve
represents the dynamic output
60 of the unit with a static load.

50
VOLTAGE

40

30

20

10

0
0 100 200 300 400 500 600 700
AMPERAGE
va_curve1 4/95 − 220 486-A

OM-228 873 Page 12

3-5. Selecting A Location

Tipping ! Do not move or operate

Movement unit where it could tip.

2
OR

Location ! Special installation may be required where gasoline or volatile ! Do not stack units. Beware of
liquids are present − see NEC Article 511 or CEC Section 20. tipping.
4 1 Lifting Forks
Use lifting forks to move unit.

3 Extend forks beyond opposite side

of unit.

18 in 2 Hand Cart
(460 mm) Use cart or similar device to move
unit.
3 Rating Label
Use rating label to determine input
power needs.
4 Line Disconnect Device
Locate unit near correct input
18 in power supply.
(460 mm)

loc_2 3/96 -Ref. 803 244-B

3-6. Standard Connection Diagram

. The proper interface kit must
be installed in the welding
2 3 5 power source/interface unit to
allow it to be connected to the
robot.
4 1 Robot (Will Vary According To
1 Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
7 6 E-Stop Cable
6
12 13 7 Gas And Motor Control Cable
8 Welding Power
Source/Interface Unit
9 Negative (−) Weld Cable
10 Workpiece
11 Voltage Sensing Lead
10 Recommended for Accu-pulse and
RMD (optional).

8 . Positive (+) voltage sensing

lead is contained in the motor
11 cable.
12 Positive (+) Weld Cable
13 Devicenet Robot/Welder
Control Cable
9

Ref. 803 244-B / Ref. 801 915-A

OM-228 873 Page 13

3-7. Optional Tandem Connection Diagram

3
4

6
7
8 13
14

12

8
1

10
9

11

805 223-A

. The proper interface kit must be 5 Robot Control Recommended for Accu-pulse and RMD
(optional).
installed in the welding power 6 E-Stop Cable (2)
source/interface unit to allow it to be
connected to the robot.
7 Gas And Motor Control Cable (2) . Positive (+) voltage sensing lead is
8 Welding Power Source/Interface contained in the motor cable.
1 Robot (Will Vary According To Unit (2)
Application) 12 Positive (+) Weld Cable (2)
2 Motor/Drive Assembly (2) 9 Negative (−) Weld Cable (2) 13 Devicenet Robot/Welder Control
3 Gas Cylinder 10 Workpiece Cable (2)
4 Gas Hose (2) 11 Voltage Sensing Lead (2) 14 Tandem Interconnect Cable

OM-228 873 Page 14

3-8. Rear Panel Receptacles And Supplementary Protectors
1 115 V 10 A AC Receptacle RC2
1
4 5 8 6 Receptacle supplies 60 Hz
single-phase power. Maximum output
2 from RC2 is limited by supplementary
protector CB1 to 10 amps.
2 Supplementary Protector CB1
3 3 Supplementary Protector CB2
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.
7 . 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 Peripheral Receptacle RC25
. RC25 is not used with Devicenet.
6 E-Stop Receptacle RC
A short across the two sockets allows
unit to weld.
7 Devicenet Receptacle RC
Network control cable connection for ro-
bot/welder communication.
8 Optional Tandem Receptacle
Connect one end of a tandem
interconnect cable to this receptacle
and the remaing end of the cable to
another tandem ready Auto-Axcess
welding power source.

Ref. 805 224-A

OM-228 873 Page 15

3-9. Connecting To Weld Terminals

. If using an electrode negative (straight polarity)

process, the volt sense lead must be connected
to the work.

6 2
3

Do not place
anything between
weld cable terminal
and copper bar.

Tools Needed:

3/4 in (19mm) Correct Installation Incorrect Installation

Ref. 803 244-B / 803 778-A

! Turn off power before connecting to cable size. 6 Copper Bar

weld output terminals. 1 Positive (+) Weld Output Terminal
Remove supplied nut from weld output
! Failure to properly connect weld 2 Negative (−) Weld Output Terminal
terminal. Slide weld cable terminal onto
cables may cause excessive heat Connect positive weld cable to Positive (+) weld output terminal and secure with nut so
and start a fire, or damage your weld terminal and negative (−) cable to that weld cable terminal is tight against
machine. Negative weld terminal. copper bar. Do not place anything
Determine total cable length in weld circuit 3 Weld Output Terminal between weld cable terminal and copper
(both positive and negative cables bar. Make sure that the surfaces of the
combined) and maximum welding 4 Supplied Weld Output Terminal Nut weld cable terminal and copper bar are
amperes. See Section 3-10 to select proper 5 Weld Cable Terminal clean.

OM-228 873 Page 16

3-10. 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 400 ft
150 ft 200 ft 250 ft 300 ft
100 ft (30 m) or Less (105 (120
(45 m) (60 m) (70 m) (90 m)
m) m)
Weld Output
Terminals
! Turn off power before 10 − 60% 60 − 100%
connecting to weld Welding
Duty Duty 10 − 100% Duty Cycle
output terminals. Amperes**
Cycle Cycle
! Do not use worn, dam-
aged, undersized, or
poorly spliced cables.

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

4/0 4/0
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)
(120) (120)

4/0 2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x70)

4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x95) (2x95)

4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x95) (2x95) (2x120)

4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x95) (2x120) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(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
600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)
Positive Negative
) * 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
700 4/0 (120)
Ref. 803 246-B (2x70) (2x95) (2x120) (3x95) (3x120) (3x120) (4x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0
800 4/0 (120)
(2x70) (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.
( ) = mm2 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-228 873 Page 17

3-11. Devicenet Receptacle

Socket Socket Information

A Chassis ground.

B +24 volts DC; available current is 1 ampere.

C C +24 volts DC common.

D
B
A E D CAN H.

E CAN L.
Ref. 804 578-A

3-12. Motor Control Receptacle Functions

Socket Socket Information

C
G
A A Not used.
J F

E B B Motor negative (−).

K
H D
C Tach A, 0 volts = low and 3.5 volts = high.

D Motor positive (+).

E Tach common.

F Gas valve, +40 volts DC when valve is on with respect to

socket K.

G Electrode sense.

H Tach +5 volts DC with respect to socket E.

J Tach B, 0 volts = low and 3.5 volts = high.

K Gas valve.
Ref. 804 578-A

3-13. E-Stop Receptacle Functions

Socket Socket Information

A B

A A short to socket B allows unit to weld.

B A short to socket A allows unit to weld.

Ref. 804 578-A

OM-228 873 Page 18

3-14. Tandem Receptacle

Socket Socket Information

A
E A Gnd.

B
D
C B Peak enable/disable, input (high).

C Peak enable/disable, output.

D Peak enable/disable, input (low).

E Not used.
Ref. 804 578-A

3-15. 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 208 230 400 460 575
Input Amperes At Rated Output 67 59 34 29 23
Max Recommended Standard Fuse Rating In Amperes
Circuit Breaker 1, Time-Delay 2 80 70 40 35 25
Normal Operating 3 100 90 50 45 35
Min Input Conductor Size In AWG 4 4 6 8 10 10
173 136 263 228 356
Max Recommended Input Conductor Length In Feet (Meters)
(53) (42) (80) (69) (108)
Min Grounding Conductor Size In AWG 4 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-228 873 Page 19

3-16. Connecting Input Power
3
= GND/PE Earth Ground
5

L1
4
L2 6
7 L3
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:
Three-Phase Input Connection

5/16 in Route input power cable

through tubing inside unit.

Route ground conductor through

current transducer to ground terminal.

804 578-A / Ref. 803 766-A / 218 005-A

! Turn Off welding power source, and applicable, use lugs of proper amperage Disconnect Device Input Power
check voltage on input capacitors capacity and correct hole size. Connections
according to Section 7-3 before Welding Power Source Input Power 3 Disconnect Device (switch shown in
proceeding. Connections the OFF position)
! Installation must meet all National 2 Strain Relief 4 Green Or Green/Yellow Grounding
and Local Codes − have only qualified Install strain relief of proper size for unit and Conductor
persons make this installation. input conductors. Route conductors (cord) 5 Disconnect Device Grounding Terminal
through strain relief and tighten screws.
! Disconnect and lockout/tagout input 6 Input Conductors (L1, L2 And L3)
power before connecting input S Use large strain relief for input conductor 7 Disconnect Device Line Terminals
conductors from unit. size 8 and larger.
Connect green or green/yellow grounding
S Use small strain relief with reducing
! Make input power connections to the
washers for input conductor size 10.
conductor to disconnect device grounding
welding power source first. terminal first.
Connect input conductors as shown in Connect input conductors L1, L2, and L3 to
! Always connect green or illustration. disconnect device line terminals.
green/yellow conductor to supply
grounding terminal first, and never to Route green or green/yellow grounding 8 Over-Current Protection
a line terminal. conductor through current transducer and
connect to welding power source grounding Select type and size of over-current protec-
1 Input Power Conductors (Customer terminal first. Then connect input conductors tion using Section 3-15 (fused disconnect
Supplied Cord) L1, L2, and L3 to welding power source line switch shown).
terminals.
Select size and length of conductors using Close and secure door on disconnect device.
Section 3-15. 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-228 873 Page 20

3-17. 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 robot pendant may be used to select programs. When Off, program selection
must be done from the welding power source front panel.

3-18. Remote Program Setting

When Remote Program Select is “On”, program selection will be determined by remote input through Devicenet 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.

OM-228 873 Page 21

 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 Eight active slots for selection of various processes, wire types, and parameters.
Process A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
MIG 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 Selection of wire type by alloys and classification.
Gas Type Selection of shielding gas being used in application.
Process Set Up Selection procedure for entering program.
Program Load Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).
Volts 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 Distance from end of wire electrode to workpiece.
WFS 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 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.
Sharp Arc 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-228 873 Page 22

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 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).
Postflow 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).
Retract 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-228 873 Page 23

4-2. Front Panel Controls (See Section 4-3)
15 14 13

4
12

Program Volts Arc Adjust

Wire Speed Amps 11

3
Process Wirefeed
Wire Type Gas 10
Gas Type Contactor
5
6

8
7 9
Setup Adjust Arc Control

. When an LED is lit, it means the related function is active.

198 993

1 Program Display PDA with File Management/WaveWriter Gas Type LED

Displays the number of the active program. software. Program name is shown in upper
When this LED is lit, turn the Adjust knob to
and lower displays (items 13 and 15).
2 Adjust Knob select the desired weld gas. Gas type choices
Turn the Adjust knob to change program 5 Setup Mode Indicators vary according to the selected weld process.
number, Setup, Arc Control, and weld The lit LED indicates which setup mode is See Table 4-1 for all gas abbreviations.
parameters. active. Setup mode parameters are shown in 6 Setup Push Button LED
3 Program Push Button LED Display Windows (see Items 13 and 15).
The LED lights to indicate one of the setup
The LED lights when the Program Push Process LED modes is active.
Button is active.
When this LED is lit, turn the Adjust knob to 7 Setup Push Button
4 Program Push Button
select the desired weld process. Choices Press button to select Process, Wire Type,
Press push button (LED lights) and turn Adjust include pulse welding (displayed as PULS),
knob to select active program. Wire Diameter, or Gas Type parameters.
Accu-pulse (ACCU), MIG welding (MIG), and
The letter C is displayed with the program RMD [Regulated Metal Deposition (optional)]. . In order for selections to be retained in
number if the program has been changed from memory, the Setup push button must be
Wire Type LED
the factory settings using the optional PDA pressed six times before any other push
with File Management/WaveWriter software When this LED is lit, turn the Adjust knob to button is pressed: once to select Process,
(see File Management/WaveWriter Owner’s select the desired wire type, wire alloy, and again to select Wire Type, again to select
Manual). size. Wire type and size choices vary Wire Alloy, again to select Wire Size,
according to the selected weld process. again to select Gas Type, and a sixth time
. The program cannot be changed through Choices may include steel (displayed as to store selections in memory. The
the front panel while welding. STL), stainless steel (SS), metal core displays will temporarily show “PROG
Press and hold button to see program name. (MCOR), aluminum (ALUM). See Table 4-1 LOAD” to indicate the data is being stored
Custom programs are named using optional for all wire abbreviations. in memory.

OM-228 873 Page 24

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
The LED lights to indicate the Arc Control The lit LED indicates whether wire speed or Command Values” mode. In the Display
button is active. Light goes out when button is amps are being displayed. Command Values mode, command
inactive. values are displayed while welding.
12 Wire Feed Speed/Amps Display Push
9 Arc Control Push Button Button . If a PDA with File Management/WaveWriter
This push button allows fine tuning inductance 13 Lower Display software is used to change wire feed units
for MIG programs, and Arc Control for (IPM, MPM) or display welding information
Press Wire Feed Speed/Amps Display button (command or actual),save the changes and
programs other than MIG. When the push to show weld amperage or wire feed speed in
button is pressed, the upper display (item 15) then turn the power to the unit off and then
lower display (the applicable LED under the on again for the changes to be carried out
shows INDU for inductance, or ARC for Arc lower display lights to indicate which is
Control to indicate which parameter is by the unit.
shown). When welding, actual value is shown.
selected for change. The range of possible 14 Volts And Arc Adjust LED’s
values is 0-99 for inductance, and 0-50 for arc If amperage was selected for display, the unit The lit LED indicates whether voltage or arc
control. Turn the Adjust knob to change the will show actual welding amperage prior to length is being displayed.
parameter value. Press button to deactivate and while welding unless the the unit is in
Display Command Values mode. Only wire 15 Upper Display
arc control mode (LED goes out).
speed command will be displayed while The upper display shows different information
10 Wire Feed/Gas/Contactor LEDs welding if the unit is set in Display Command depending on the active function of the unit
The Wirefeed LED lights when the wire feeder Values mode, even if the Wire Feed and the weld process being used. When the
is energized. For example, when the front Speed/Amps Display button is pressed. display shows voltage (for a MIG process),
panel Jog or Retract button is pressed, the the Volts LED lights. When it shows arc adjust
Wirefeed LED lights. . Displays show actual or command values [for a pulsed and RMD (optional) weld
as determined by configuration menu process], the Arc Adjust LED lights. However,
The Gas LED lights when the gas valve is
when using a PDA with File Management/ during any weld process (MIG and pulse), the
energized.
WaveWriter software. Command values unit will display actual arc voltage unless a
The Contactor LED lights when the output are displayed prior to welding and actual PDA with File Management/WaveWriter
contactor is energized, making the weld values are displayed while welding unless software has set the unit in the ”Display
output terminals live. a PDA with File Management software Command Values” mode.

Table 4-1. Welding Wire And Gas Abbreviations*

Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation
Steel STL E70, E100, E120 100% CO2, CO2
90% Argon/10% CO2, C10
85% Argon/15% CO2, C15
75% Argon/25% CO2, C25
95% Argon/5% CO2, C5
95% Argon /5% O2, OX5
98% Argon/2% O2 OX2
Stainless Steel SS 308, 309, 312, 316 98% Argon, 2% O2 OX2
(81Ar/18HE/1CO2 Tri Gas
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO 2 Tri Gas
MIG/RMD/Accu-pulse)
Cored Tubular Wire MCOR 71, 76, 86R, 409, 90% Argon/10% CO2 C10
439
98% Argon/2% O2 OX2
Aluminum ALUM 4XXX, 5XXX 100% Argon ARGN
* Not all wire types may be available with your unit.

OM-228 873 Page 25

4-4. Front Panel Switches

1 4

2
Ref. 803 246-B

1 Power Switch AUTO 6 Wirefeed LED

450
Turns unit On or Off. Wirefeed LED illuminates when wire feeds or
AUTO 450 indicates the software being retracts.
The power-up sequence may last up to 30 loaded.
seconds before the unit is ready to weld. 7 Retract Push Button
During power-up, the front panel will display 2 Contactor LED
messages indicating the status of the unit. The Contactor LED illuminates when weld output is Press button to retract wire. Wirefeed LED
first message is: energized. illuminates when Retract push button is
pressed.
NET 3 Purge Push Button
WAIT Auto-Threading feature is activated by
Press button to purge gas line.
pressing the Jog and Retract buttons
NET WAIT is an abbreviation for ”network 4 Gas LED simultaneously. Pressing the Jog, Purge, or
updating” and means the internal control trigger switch will turn off the Auto-Threading
Gas LED illuminates when Purge push button
network is powering up. The next message is feature.
is pressed.
DTEC ROBT (Robot Type) 5 Jog Push Button 8 PDA Port
The final message is Press button to jog wire. 9 PC Port

OM-228 873 Page 26

4-5. Reset Mode
. Reset mode is not active when
Program Lock is enabled.
RST
The reset mode allows the operator to
reload factory program settings for all
NO 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 RST CYCL

YES YES PWR

Rotate Adjust knob to change NO Press the Arc Control button to Cycl Pwr message appears on the display
to YES. confirm the reset. when programs complete loading.
The reset message is displayed for Turn power off, wait 10 seconds, and turn
2 seconds while factory program power back on again to complete the reset
settings are being reloaded. operation.
During the reset mode the following
factory default programs are loaded
. After Reset is complete, be sure to load
appropriate programs that contain the
into the unit:
correct wire size, process, and shielding gas
for the welding operation
Program 1 Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2 MIG
.035 Mild Steel
75% Argon, 25% CO2
Program 3 Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
Program 4 Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5 MIG
.045 Mild Steel
75% Argon, 25% CO2
Program 6 Accu-pulse
.045 Mild Steel
90% Argon, 10% O2
Program 7 Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8 MIG
.052 Mild Steel
75% Argon, 25% CO2
198 993 / 803 246-B

OM-228 873 Page 27

 SECTION 5 − MAINTENANCE
5-1. Routine Maintenance

! Disconnect power . Maintain more often

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

Every
6
OR
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-228 873 Page 28

 SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read and follow these precautions.

6-1. Symbol Usage

OM-228 873G - 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 This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex- SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text. bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

6-2. Servicing Hazards

The symbols shown below are used throughout this manual FIRE OR EXPLOSION hazard.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Do not place unit on, over, or near combustible
to avoid the hazard. surfaces.
D 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 Wear safety glasses with side shields or face
ELECTRIC SHOCK can kill. shield during servicing.
D Be careful not to short metal tools, parts, or
D Do not touch live electrical parts. wires together during testing and servicing.
D 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- HOT PARTS can cause severe burns.
cifically requires an energized unit.
D Do not touch hot parts bare handed.
D Insulate yourself from ground by standing or working on dry insulat- D Allow cooling period before working on
ing mats big enough to prevent contact with the ground. equipment.
D Do not leave live unit unattended. D To handle hot parts, use proper tools and/or
D If this procedure requires an energized unit, have only personnel wear heavy, insulated welding gloves and
familiar with and following standard safety practices do the job. clothing to prevent burns.
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.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
SIGNIFICANT DC VOLTAGE exists after removal of
D Always wear a face shield and long sleeves
input power on inverters. 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.

STATIC (ESD) can damage PC boards. D Turn Off welding power source and wire feeder
or stop engine before making or changing me-
D Put on grounded wrist strap BEFORE handling ter lead connections.
boards or parts. D Use at least one meter lead that has a self-
D Use proper static-proof bags and boxes to retaining spring clip such as an alligator clip.
store, move, or ship PC boards. D Read instructions for test equipment.

OM-228 873 Page 29

 FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.
D Use lifting eye to lift unit only, NOT running D Allow cooling period; follow rated duty cycle.
gear, gas cylinders, or any other accessories. D Reduce current or reduce duty cycle before
D Use equipment of adequate capacity to lift and starting to weld again.
support unit. D Do not block or filter airflow to unit.
D 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
communications equipment.
MOVING PARTS can cause injury. D Have only qualified persons familiar with
electronic equipment install, test, and service
D Keep away from moving parts such as fans. H.F. producing units.
D Keep away from pinch points such as drive D The user is responsible for having a qualified electrician prompt-
rolls. ly correct any interference problem resulting from the installa-
tion.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance as D If notified by the FCC about interference, stop using the
necessary. equipment at once.
D Keep hands, hair, loose clothing, and tools D Have the installation regularly checked and maintained.
away from moving parts. D Keep high-frequency source doors and panels tightly shut, keep
D Reinstall doors, panels, covers, or guards spark gaps at correct setting, and use grounding and shielding to
when maintenance is finished and before re- minimize the possibility of interference.
connecting input power.

READ INSTRUCTIONS.
MAGNETIC FIELDS can affect Implanted
D Use Testing Booklet (Part No. 150 853) when
Medical Devices. servicing this unit.
D Wearers of Pacemakers and other Implanted D Consult the Owner’s Manual for welding safety
Medical Devices should keep away from serv- precautions.
icing areas until consulting their doctor and the D Use only genuine replacement parts from the
device manufacturer. 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 Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.

6-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them, or using a
Electric And Magnetic Fields cable cover.

Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
5. Connect work clamp to workpiece as close to the weld as possi-
frequency electric and magnetic fields is a human-health hazard.”
ble.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Implanted Medical Devices:
may wish to minimize your exposure to electromagnetic fields when Implanted Medical Device wearers should consult their doctor and the
welding or cutting. device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
To reduce magnetic fields in the workplace, use the following If cleared by your doctor, then following the above procedures is recom-
procedures: mended.
OM-228 873 Page 30
 SECTION 7 − TROUBLESHOOTING
7-1. Set Value Mode

Program Volts Arc Adjust

Wire Speed Amps

Process Wirefeed 4
Wire Type Gas
Gas Type Contactor

1 2
Setup Adjust Arc Control

The Set Value mode is a troubleshooting tool display windows briefly shows SET VALU and active display will blink to indicate the value
that allows certain robot command values to the blinking LED’s under the display windows that can be changed.
be manually over-ridden. indicate whether Volts, Arc Adjust, or Wire
Rotate the Adjust knob to change values.
Speed can be changed turning the Adjust
1 Setup Push Button knob. Exit the Set Value mode by pressing the Setup
2 Arc Control Push Button and Arc Control push buttons at the same time
Depending on the defined weld process,
or turning power source off and then back on
3 Adjust Knob either volts (MIG) or arc adjust [pulse,
again.
4 Wire Feed Speed/Amps Display Push Accu-pulse, or RMD (optional)] can be
Button changed in the top display. Wire speed can be Set Value mode overrides robot wire feed
changed in the bottom display. Press the Wire speed, voltage, and trim commands. To weld
Enter the Set Value mode by pressing the Feed Speed/Amps push button to toggle in this mode, the robot only needs to provide
Setup and Arc Control push buttons at the between selecting information in the top a contactor signal, and voltage and wire feed
same time. When in the Set Value mode the display or bottom display. The LED under the speed will be ignored.

OM-228 873 Page 31

 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 ERR ERR ERR

TACH MOTR WFS STRT STOP FLOW

Indicates a Indicates a motor Indicates a wire Indicates an arc Indicates an arc Indicates a gas
tachometer error. error. feed speed error. start error. stop error. flow error.

ERR ERR ERR ERR ERR ERR

COOL GND STUK TEMP LINE ARC

Indicates a coolant Indicates a ground Indicates a wire Indicates a Indicates a line Indicates an arc
flow error. current error. stuck error. temperature error. error. error.

ERR TACH ERR STOP ERR STUK

• Tach error for Tach A occurs 2 seconds • The stuck error occurs if the welding wire
after the loss of tachometer feedback. The • The stop error occurs as result of sticks to the workpiece at the end of a weld.
motor speed is regulated through the obstructions in the wire feed system or a May be caused by poor weld conditions.
monitoring of voltage and current. Press faulty wire drive system. Check wire feed The error may be cleared by cutting wire
Jog/Purge button to clear error. and wire drive systems. Press Jog/Purge from workpiece, and pressing the Jog/
button to clear error. Purge button.
• Tach error for Tach B occurs 2 seconds
after the loss of tachometer feedback. The ERR FLOW ERR TEMP
motor speed is regulated through the • The temperature error indicates welding
monitoring of voltage and current. Press • The flow error indicates no gas flow to the power source has overheated and
Jog/Purge button to clear error. gun. The error may be reset by shutdown. The error may be cleared by
ERR MOTR reestablishing gas flow to the gun, and then allowing unit to cool down, and pressing the
pressing the Jog/Purge button. Jog/Purge button. If problem persists,
• The motor error indicates that the motor check fan motors and thermistors for proper
has been drawing too much current for too operation. If unit is not overheated, check in-
long. To remedy this, reduce the wire feed ERR COOL
put line voltage. If input line voltage is okay,
speed or the wire feeder torque load/duty contact nearest factory authorized Service
cycle. Press Jog/Purge button to clear error. • The cool error indicates no coolant flow in
water flow switch option. The error may be Agent.
ERR WFS reset by reestablishing coolant flow to the ERR LINE
• The wire feed speed error indicates actual gun, and then pressing the Jog/Purge • The line error indicates input power is
wire feed speed does not match wire feed button. outside of unit operating range. Check and
speed command. Press Jog/Purge button correct input power. Press Jog/Purge
to clear error. ERR GND button to clear error.
ERR STRT ERR ARC
• The ground current error occurs if weld
• The start error, when enabled, occurs if the current is detected in the earth ground • The arc error indicates an arc outage
trigger is held longer than three seconds connection. May be caused by a conductor occurred possibly from a wire feeder error
without an arc start. The error may be making contact with unit chassis. Check or power source error. Check wire feeder
cleared by releasing the trigger, and and repair feeder weld connections. Turn and power source. Press Jog/Purge button
pressing the Jog/Purge button. power off and back on to clear error. to clear error.

OM-228 873 Page 32

7-2. Diagnostics (Continued)

WELD MOTR PLS LOW ROBT E

WAIT COM WAIT WFS MEM STOP

Indicates a weld Indicates a motor Indicates a UIM Indicates a low WFS Indicates a CRC Indicates an
cycle wait error. communication error. communication error. command error. robot memory error. emergency stop error.

RMD OVER UNIT OVER

DONE AVG COMM CRNT

Indicates RMD Indicates an over Indicates a CRC Indicates an
demo is done. average current error. PCM bus error. overcurrent error.

WELD WAIT ROBT MEM UNIT COMM

• The weld wait error indicates unit was not • The robot memory error indicates robot • The unit communication error indicates
ready for a weld sequence. Press Jog/ lost memory data. Press Jog/Purge button the data bus on the PCM board is not
Purge button to clear error. to clear error. functioning properly. Press Jog/Purge
button to clear error.
MOTR COM E STOP OVER CRNT
• The motor communication error indi- • The emergency stop error occurs if the • The over current error indicates welding
cates motor board lost data communica- user presses an emergency stop button. power source primary current of the inverter
tions. Press Jog/Purge button to clear error. Reset the emergency stop button and press is too high. Turn welding power source off
If condition persists, contact nearest factory Jog/Purge button to clear error. Only applies and disconnect unit for servicing.
authorized service agent. to units equipped with E stop option. Attempting to reset the display to
PLS WAIT continue welding may further damage
RMD DONE internal components. A complete
• The uim communication error indicates prepower check of the unit is needed
user interface board lost data • The RMD done message indicates the
including resistance measurements of R1
communications. Press Jog/Purge button RMD demo is completed. Pressing
Jog/Purge button will change the screen to and R8 resistors on welding power source
to clear error. If condition persists, contact Interconnect board. Resistors should
nearest factory authorized service agent. CYCL PWR on the display. Turn unit power
off and back on again. measure 30K ohms. Visually inspect
LOW WFS electrolytic capacitors C1 and C2 for any
OVER AVG possible damage. In the event of an over
• The low wire feed speed error indicates voltage condition, R1 and R8 could open
actual wire feed speed is lower than wire • The over average error indicates that potentially causing an imbalance in the
feed speed command. Check for current is outside the average range for the power circuit. This condition would create
obstructions in the wire feed system or a set program parameters. Check and correct excessive current in the inverter primary
faulty wire drive system. Press Jog/Purge program parameters. Press Jog/Purge transformer and result in the OVER CRNT
button to clear error. button to clear error. error.

OM-228 873 Page 33

7-2. Diagnostics (Continued)

REL TRIG ERR

TRIG STUK UNKN

Indicates a contactor Indicates a trigger Indicates an
on error. closed error. unknown error.

REL TRIG ERR UNKN

• The release trigger error indicates the • The unknown error indicates an error was
user held the gun trigger after an E stop was sent from the PCM board to the UIM, but
reset causing the contactor to remain on. error condition is unknown. Make sure
Press Jog/Purge button to clear error. welding power source is isolated from the
TRIG STUK welding fixture. Press Jog/Purge button to
• The trigger stuck error indicates the user clear error.
held the gun trigger during power up.
Release trigger and turn power off and back
on.

OM-228 873 Page 34

7-3. Removing Cover and Measuring Input Capacitor Voltage
Turn Off welding power source, and
! 900 Volts DC can be present on the capacitor bus disconnect input power.
and significant DC voltage can remain on
capacitors after unit is Off. Always check the Remove cover
voltage on both inverter assemblies as shown to be 1 Power Interconnect Board
Tools Needed: sure the input capacitors have discharged before PC2
working on unit.
5/16 in 2 Voltmeter
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.
1 Proceed with job inside unit.
2 Reinstall cover when finished.

+ lead to left bus terminal, − lead to right bus terminal

1
2

+ lead to left bus terminal, − lead to right bus terminal

Typical Bleeder Resistor
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-228 873 Page 35

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
1
diagnostic LED’s.
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 Indicates −25 volts DC is present on process control module PC4

Off Indicates −25 volts DC is not present on process control module PC4
2 On Indicates +25 volts DC is present on process control module PC4
Off Indicates +25 volts DC is not present on process control module PC4
3,4 On See Network Status Table in Section 7-10
Off See Network Status Table in Section 7-10

OM-228 873 Page 36

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
1 diagnostic LED’s.
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 / 804 579-A

7-7. Diagnostic LED’s On Wire Feed Module PC6

LED Status Diagnosis

1 On Indicates +15 volts DC is present on wire feed module PC6

Off Indicates +15 volts DC is not present on wire feed module PC6
2 On Indicates +5 volts DC is present on wire feed module PC6
Off Indicates +5 volts DC is not present on wire feed module PC6
3,4 On See Network Status Table in Section 7-10
Off See Network Status Table in Section 7-10

OM-228 873 Page 37

7-8. User Interface Module PC7 Diagnostic LED’s

2 LED1

LED2

218 559-A / 804 579-A

1 User Interface Module PC7 Reinstall cover after checking diagnostic Dip switches are used to identify each
Diagnostic LED’s are visible inside unit, LED’s. circuit board on the internal network. Dip
located on PC7 mounted behind the front switch settings are different for each circuit
panel. 2 Dip Switch S1 board. For proper operation, do not change
Refer to Section 7-9 for information on dip settings from those shown.
diagnostic LED’s. 3 Dip Switch S2

7-9. Diagnostic LED’s On User Interface Module PC7

LED Status Diagnosis

1, 2 On See Network Status Table in Section 7-10

Off See Network Status Table in Section 7-10

OM-228 873 Page 38

7-10. 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 The circuit board is not on-line with the network or there is no power applied to the circuit board.
Green The circuit board is operating normally and the on-line connection is made with the network.
Flashing Green The circuit board is wait for an on-line connection to be made with the network.
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 There is no power applied to the circuit board or the board software is not executing its functions.
Green The circuit board is operating normally.
Flashing Red The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.
Red The circuit board has encountered an unrecoverable fault.

OM-228 873 Page 39

7-11. Troubleshooting

Trouble Remedy
No weld output; completely inoperative Place line disconnect in On position (see Section 3-16).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-16).
Check for proper input power connections (see Section 3-16).
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 3-10).
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 3-8).
Wire does not feed. Check supplementary protector CB2 and reset if necessary (see Section 3-8).
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 robot contactor status.
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-228 873 Page 40

Notes

OM-228 873 Page 41

 SECTION 8 − ELECTRICAL DIAGRAMS

Figure 8-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)

OM-228 873 Page 42
 228 745-C (Part 1 Of 2)

OM-228 873 Page 43

 Figure 8-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)

OM-228 873 Page 44

 228 745-C (Part 2 Of 2)

OM-228 873 Page 45

 Ref. 219 267-B

Figure 8-3. Circuit Diagram For Peripheral/Motor Interface

OM-228 873 Page 46

Notes

OM-228 873 Page 47

 SECTION 9 − PARTS LIST

. Hardware is common and

not available unless listed.

2 1

4 − Fig 9-3

7 − Fig 9-4
5 − Fig 9-2

6 17
9

19

18
5

18
10
16 − Fig 9-5
8
11
15
12 9
13
14
15

Ref. 804 580-A

Figure 9-1. Main Assembly

OM-228 873 Page 48

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-1. Main Assembly

. . . 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
15 . Hardware is common and
not available unless listed.
2 1
3

4
5
6
7
12 8
13 9
11 33
10 34
35
6 17 16
7 18

19

32
31 20 21
30
23 24
29
25

27 23

36
13
28
26
22
23
38
37
802 955-A

Figure 9-2. Windtunnel Assembly LH And RH

OM-228 873 Page 49

 Item Dia. Part
No. Mkgs. 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 . . . . . . 235305 . . . 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-228 873 Page 50

 1 . Hardware is common and
not available unless listed.

2
3

5
11 6

10

9
8

802 916-B

Figure 9-3. Top Tray Assembly

Item Dia. Part
No. Mkgs. 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-228 873 Page 51

 4
3 . Hardware is common and
not available unless listed.
1 2

15

14 7

13
8

12
9

11

10
804 581-B

Figure 9-4. Rear Panel Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 9-4. Rear Panel Assembly (Fig 9-1 Item 8)

... 1 . . . . . . . . . . . . . . . . 217297 . . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . . . 210475 . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . . . 210358 . . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . . . 210505 . . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . . . 224012 . . . Plate, Rotation Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . . . 198956 . . . Receptacle, Devicenet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . . . 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . CB1 . . . . . . 083432 . . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . . 1
... 9 . . . . CB2 . . . . . . 093995 . . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . . 1
... 10 . . . . PC11 . . . . . . 216213 . . . Circuit Card Assy, Motor Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . . ♦237094 . . . Circuit Card Assy, Tandem Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . . . 216596 . . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . . . 225955 . . . Plate, Mounting E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . . . 300007 . . . E-Stop Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . RC2 . . . . . . 604176 . . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦OPTIONAL
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-228 873 Page 52

 . Hardware is common and
2 not available unless listed.
1

23
8 4
7
9 3
21
22

20
6
7
5
19 8
14
7
13 8

12

9
18

15
10
11

16
17
17

803 249-D

Figure 9-5. Front Panel Assembly

Item Dia. Part
No. Mkgs. 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 ................ 233575 . . . Panel, PC Card Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . FM . . . . . . . 196313 . . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . . 2
... 6 . . . . PC13 . . . . . . 208071 . . . Circuit Card Assy,ISO/COMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . C6, C7, C8 . . . 206878 . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 8 ................ 213102 . . . Choke, Common Mode w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 ................ 025248 . . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . 2
... 10 ................ 207897 . . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 ................ 210866 . . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . RC5 . . . . . . 214664 . . . Receptacle, Common Mode Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-228 873 Page 53

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-5. Front Panel Assembly (Fig 9-1 Item 14) (Continued)

... 13 ................ 216966 . . . Cover, Connector D-sub 9 pin Male w/Chain . . . . . . . . . . . . . . . . . . . . . . 1

... 14 ................ 216965 . . . Cover, Connector D-sub 9 skt Female w/Chain . . . . . . . . . . . . . . . . . . . . 1
... 15 ................ 219843 . . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 ................ 207896 . . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 ................ 186621 . . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 PB1, PB2, PB3 . . 199443 . . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . . 3
... 19 ................ 226815 . . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 ................ 210865 . . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 ................ 207893 . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 ................ 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 ................ 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-228 873 Page 54

 Effective January 1, 2008
(Equipment with a serial number preface of LJ or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
Miller distributor. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Miller’s True Blue® Limited Warranty shall not apply to:
writing within thirty (30) days of such defect or failure, at which
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear.
Miller shall honor warranty claims on warranted equipment listed (Exception: brushes, slip rings, and relays are
need. Most replacement below in the event of such a failure within the warranty time
covered on Bobcat, Trailblazer, and Legend
parts can be in your periods. All warranty time periods start on the delivery date of the
models.)
hands in 24 hours. equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American 2. Items furnished by Miller, but manufactured by others,
Support distributor or eighteen months after the equipment is shipped to such as engines or trade accessories. These items are
Need fast answers to the an International distributor. covered by the manufacturer’s warranty, if any.
tough welding questions? 1. 5 Years Parts — 3 Years Labor 3. Equipment that has been modified by any party other
Contact your distributor. than Miller, or equipment that has been improperly
* Original main power rectifiers only to include SCRs,
The expertise of the diodes, and discrete rectifier modules installed, improperly operated or misused based upon
distributor and Miller is industry standards, or equipment which has not had
there to help you, every 2. 3 Years — Parts and Labor
reasonable and necessary maintenance, or equipment
step of the way. * Transformer/Rectifier Power Sources which has been used for operation outside of the
* Plasma Arc Cutting Power Sources specifications for the equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year — Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers
Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Field Options
(NOTE: Field options are covered under True Blue® Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year — special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
* Bernard-Branded Mig Guns (No Labor) state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2008-01
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

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.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
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.

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