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Common questions
Common Questions
27 totalHow do I perform a system reset on the Miller 350P?
To perform a system reset that returns the unit to all original factory settings, press and hold the SETUP button while turning on the welding power source. SRST will appear on the left display and OFF on the right display. Rotate the left knob until ON appears on the right display, then press SETUP to apply the system reset function. Wait until the unit completely reboots before performing any other operations. (Page 29)
What is Jog Mode on the Miller 350P and when does it activate?
Jog Mode activates when the gun trigger is pressed and held for more than 3 seconds without striking an arc. In this mode, weld power automatically shuts off and the displays will show JOG MODE. For MIG guns, shielding gas will shut off after 1 minute and wire will feed for up to 2 minutes before the wire drive system automatically shuts off. (Page 23)
How do I adjust the inductance setting in MIG welding mode on the Miller 350P?
In MIG welding mode, press the ARC CONTROL button to enter the Arc control menu where INDU will appear on the left display. Adjust the right knob to change the inductance setting, which ranges from 0-99. Low inductance (0 setting) produces a narrow weld bead while high inductance (99 setting) produces a wider bead. Changing inductance adjusts the fluidity of the puddle. Refer to the MIG welding chart for suggested inductance settings for your wire and gas types. (Page 25)
What are the main specifications of the Miller 350P welder?
The Miller 350P has a rated output of 350A at 32Vdc with 40% duty cycle, and can handle wire types from .023-.045 inches in diameter with feed speeds of 50-700 IPM. The unit measures 34 inches high by 19 inches wide by 41 inches deep and weighs 181 lbs. It operates in a temperature range of -20°C to +40°C and supports MIG (GMAW), Pulsed MIG (GMAW-P), and Flux Cored (FCAW) welding processes. (Page 9)
How do I set up the Miller 350P welder for the first time?
Start by installing the work clamp to the negative output terminal, then install the welding gun through the opening until it bottoms against the drive assembly and secure with the gun securing knob. Connect the gun trigger plug and tighten the threaded collar. Install the gas supply by connecting the regulator/flowmeter to the rear panel with a typical flow rate of 20 cfh. Finally, thread the welding wire through the wire guides and drive rolls, adjusting hub tension so a slight force is needed to turn the spool. (Pages 10-19)
What should I do if the Miller 350P overheats during welding?
If the unit overheats, thermistors RT1 and RT2 will open, stopping the output while the cooling fan continues to run. You must wait at least fifteen minutes for the unit to cool before attempting to weld again. To prevent future overheating, reduce amperage or voltage, or reduce the duty cycle before resuming welding, as exceeding the duty cycle can damage the unit and void warranty. (Pages 9-10, 30)
Show 21 more questions
How do I troubleshoot when there is no weld output but wire feeds?
What does the H--- message mean on the Miller 350P display?
How do I change the drive rolls on the Miller 350P?
What are the preflow and postflow timer settings used for on the Miller 350P?
What is the duty cycle for the Miller 350P?
Which welding guns are compatible with the Miller 350P?
How do I set the correct polarity for different wire types?
How do I install the gas supply on the Miller 350P?
How do I install the work clamp on the Miller 350P?
Where can I find information about machine specifications and volt-ampere curves?
How do I install the work clamp on my Miller 350P?
What safety information should I review before using the Miller 350P?
What welding processes does the Miller 350P support?
What is the duty cycle for the Miller 350P and how do I prevent overheating?
How do I thread welding wire for the Roughneck gun?
What electrical service requirements does the Miller 350P have?
How do I install and adjust the wire spool and hub tension?
How do I connect an XR Edge or XR-A gun to my Miller 350P?
What is the volt-ampere curve and where can I find it?
How do I set up the gun polarity for different wire types?
What safety precautions should I read before using the Miller 350P?
Full Manual
59 pages
Millermatic 350 And Millermatic 350P with Roughneck 4012 Gun Processes Description Arc Welding Power Source and Wire Feeder
Om-1327
213 814F
October 2004 Visit our website at www.MillerWelds.com MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding
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 catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Thank 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 will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard. Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. From Miller to You Mil_Thank 7/03
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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 2 − Consignes De Sécurité − À Lire Avant Utilisation
5 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. 7 . . . . . . . . . . . 2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 3 − Installation
9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Duty Cycle And Overheating 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Volt-Ampere Curve 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Installing Work Clamp 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Installing Welding Gun/Cable Holder 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Installing Welding Gun 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Connecting Spoolmatic) 15A Or 30A Gun 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Connecting XR Edge, XR-A Gun, Or XR-A Python 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Setting Gun Polarity For Wire Type 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. Installing Gas Supply 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11. Installing Wire Spool and Adjusting Hub Tension 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12. Electrical Service Guide 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13. Selecting A Location And Connecting 3-Phase Input Power 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14. Selection A Location And Connecting 1-Phase Input Power 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15. Threading Welding Wire For Roughneck Gun 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16. Threading Welding Wire For XR Edge, XR-A Gun, Or XR-A Python 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17. Threading Welding Wire Through XR Guns 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 4 − Operation
22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. MIG Mode 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Jog Mode 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Weld Status 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. MIG Gun-On-Demand 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Pulse MIG Mode Voltage Adjustment 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Pulse MIG Gun-On-Demand 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Tip Saver 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Weld Parameters For MIG And Pulse Mode 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 5 − Programming
25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. MIG Welding Mode 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Pulse MIG Welding Mode 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Timers 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Arc Times And Arc Starts 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. System Reset 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table Of Contents
Section 6 − Maintenance &Troubleshooting
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Overheating 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Changing Drive Roll and Wire Inlet Guide 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Troubleshooting 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Help Displays 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 7 − Electrical Diagram
36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 8 − Parts List
38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warranty
OM-1327 Page 1
Section 1 − Safety Precautions - Read Before Using
som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conduc- tor first − double-check connections. Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breath- ing air is safe. Do not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
OM-1327 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RAYS can burn eyes and skin. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant mate- rial (leather and wool) and foot protection. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. WELDING can cause fire or explosion. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. FLYING METAL can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. HOT PARTS can cause severe burns. Do not touch hot parts bare handed. Allow cooling period before working on gun or torch. MAGNETIC FIELDS can affect pacemakers. Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged. Protect compressed gas cylinders from excessive heat, mechani- cal shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fit- tings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.
OM-1327 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. MOVING PARTS can cause injury. Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can cause injury. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. MOVING PARTS can cause injury. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive elec- tronic equipment. 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. 1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
OM-1327 Page 4 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi- ami, FL 33126 (phone: 305-443-9353, website: www.aws.org). National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web- site: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W
1R3
(phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- ternational.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www. sparky.org). OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices−−phone for Region 5, Chicago, is 312−353−2220, website: www.osha.gov). 1-6. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power- frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures:
OM-1327 Page 5
Section 2 − Consignes De Sécurité − À Lire Avant
Utilisation
som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie « NOTA » ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et aux directives ci-dessous afin de connaître les me- sures à prendre pour éviter tout danger. 2-2. Dangers relatifs au soudage à l’arc Les symboles ci-après sont utilisés tout au long du présent manuel pour attirer l’attention sur les dangers potentiels et les identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et suivre les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité énoncées ci-après ne font que résumer le contenu des normes de sécurité mentionnées à la section 2-4. Lire et respecter toutes ces normes. L’installation, l’utilisation, l’entretien et les réparations ne doi- vent être confiés qu’à des personnes qualifiées. Pendant l’utilisation de l’appareil, tenir à l’écart toute personne, en particulier les enfants.Les Décharges Électriques
peuvent être mortelles. Un simple contact avec des pièces sous tension peut causer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est en fonctionnement. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension. En soudage semi−automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal mis à la terre présente un danger. Ne jamais toucher aux pièces électriques sous tension. Porter des gants et des vêtements de protection secs et exempts de trous. S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi- tifs isolants suffisamment grands pour empêcher tout contact physique avec la pièce ou la terre. Ne pas se servir d’une source de courant alternatif dans les zones humi- des, les endroits confinés ou là où on risque de tomber. Ne se servir d’une source de courant alternatif QUE si le procédé de souda- ge l’exige. Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser- vir de la fonction de télécommande si l’appareil en est équipé. Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal- lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor- mes de sécurité). Installer et mettre à la terre correctement l’appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux. Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assu- rer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. Pour exécuter les branchements d’entrée, fixer d’abord le conducteur de mise à la terre adéquat et contre−vérifier les connexions. Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est ni endommagé ni dénudé ; le remplacer immédiatement s’il est en- dommagé − tout câble dénudé peut causer une électrocution. Mettre l’appareil hors tension quand on ne l’utilise pas. Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou mal épissés. Ne pas s’enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode d’une autre machine. N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le− champ les pièces endommagées. Entretenir l’appareil conformément au présent manuel. Porter un harnais de sécurité quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le câble de retour de façon à obtenir un bon contact métal sur métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un même terminal de sortie. Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique. Arrêter les convertisseurs, débrancher le courant électrique et dé- charger les condensateurs d’alimentation selon les instructions énoncées à la section Entretien avant de toucher les pièces. Le soudage génère des fumées et des gaz dont l’inhalation peut être dangereuse pour la santé. LES FUMÉES ET LES GAZ peuvent être dangereux. Se tenir à distance des fumées et ne pas les inhaler. À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Si la ventilation est insuffisante, utiliser un respirateur à adduction d’air agréé. Lire les fiches techniques de santé−sécurité (FTSS) et les instruc- tions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. Ne travailler dans un espace clos que s’il est bien ventilé ou porter un respirateur à adduction d’air. Demander toujours à un surveillant dû- ment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent se substituer à l’air, abaisser la teneur en oxygène et causer des lésions ou des accidents mortels. S’assurer que l’air est respira- ble. Ne pas souder à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irri- tants. Ne pas souder de métaux munis d’un revêtement, tels que la tôle d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement n’ait été enlevé dans la zone de soudage, que l’endroit soit bien venti- lé, et si nécessaire, porter un respirateur à adduction d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dé- gager des fumées toxiques lorsqu’on les soude.
OM-1327 Page 6 Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour re- garder (voir les normes de sécurité ANSI Z49.1 et Z87.1). Porter des lunettes de sécurité à écrans latéraux sous le masque. Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder l’arc. Porter des vêtements de protection en matière durable et ignifuge (cuir ou laine) et des chaussures de sécurité. Le soudage effectué sur des récipients fermés tels que des réservoirs, des fûts ou des conduites peut causer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, les pièces chaudes et les équipements chauds peuvent causer des incendies et des brûlures. Le contact accidentel de l’électrode avec tout objet métallique peut causer des étincelles, une explosion, un surchauf- fement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. LE SOUDAGE peut causer un incen- die ou une explosion. Se protéger et protéger les tiers de la projection d’étincelles et de mé- tal chaud. Ne pas souder à un endroit où des étincelles peuvent tomber sur des substances inflammables. Placer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneuse- ment avec des protections agréées. Des étincelles et des matières en fusion peuvent facilement passer même par des fissures et des ouvertures de petites dimensions. Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi- mité. Le soudage effectué sur un plafond, un plancher, une paroi ou une cloison peut déclencher un incendie de l’autre côté. Ne pas souder des récipients fermés tels que des réservoirs, des fûts ou des conduites, à moins qu’ils n’aient été préparés conformément à l’AWS F4.1 (voir les normes de sécurité). Brancher le câble sur la pièce le plus près possible de la zone de sou- dage pour éviter que le courant ne circule sur une longue distance, par des chemins inconnus, et ne cause des risques d’électrocution et d’in- cendie. Ne pas utiliser le poste de soudage pour dégeler des conduites ge- lées. En cas de non utilisation, enlever la baguette d’électrode du porte− électrode ou couper le fil au raz du tube−contact. Porter des vêtements de protection exempts d’huile tels que des gants en cuir, une chemise en tissu épais, des pantalons sans revers, des chaussures montantes et un masque. Avant de souder, retirer tout produit combustible de ses poches, tel qu’un briquet au butane ou des allumettes. LES PARTICULES PROJETÉES peu- vent blesser les yeux. Le soudage, le burinage, le passage de la pièce à la brosse métallique et le meulage provoquent l’émission d’étincelles et de particules métalli- ques. Pendant leur refroidissement, les soudures risquent de projeter du laitier. Porter des lunettes de sécurité à écrans latéraux agréés, même sous le masque de soudage. LES ACCUMULATIONS DE GAZ peu- vent causer des blessures ou même la mort. Couper l’alimentation en gaz protecteur en cas de non utilisation. Veiller toujours à bien ventiler les espaces confinés ou porter un respira- teur à adduction d’air agréé. LES PIÈCES CHAUDES peuvent cau- ser des brûlures graves. Ne pas toucher les pièces chaudes à main nue. Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche. LES CHAMPS MAGNÉTIQUES peuvent perturber le fonctionnement des stimu- lateurs cardiaques. Les personnes qui portent un stimulateur cardiaque doivent se tenir à distance. Ils doivent consulter leur médecin avant de s’appro- cher d’un lieu où on exécute des opérations de sou- dage à l’arc, de gougeage ou de soudage par points. LE BRUIT peut affecter l’ouïe. Le bruit de certains processus et équipements peut affecter l’ouïe. Porter des protecteurs d’oreille agréés si le niveau sonore est trop élevé. Les bouteilles de gaz protecteur contiennent du gaz sous haute pression. Toute bouteille endommagée peut exploser. Comme les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. Les
Bouteilles
endommagées peuvent exploser. Protéger les bouteilles de gaz comprimé de la chaleur excessive, des chocs mécaniques, du laitier, des flammes nues, des étincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte−bouteilles pour les empêcher de tomber ou de se renverser. Tenir les bouteilles éloignées des circuits de soudage ou autres cir- cuits électriques. Ne jamais poser une torche de soudage sur une bouteille de gaz. Ne jamais mettre une électrode de soudage en contact avec une bou- teille de gaz. Ne jamais souder une bouteille contenant du gaz sous pression − elle risquerait d’exploser. N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et raccords adéquats pour l’application envisagée ; les maintenir en bon état, ainsi que les pièces connexes. Détourner la tête lorsqu’on ouvre la soupape d’une bouteille. Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa- tion ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz compri- mé, les équipements associés et les publications P−1 de la CGA, mentionnées dans les normes de sécurité.
OM-1327 Page 7 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO-
Sion
Ne pas placer l’appareil sur une surface inflam- mable, ni au−dessus ou à proximité d’elle. Ne pas installer l’appareil à proximité de produits inflammables. Ne pas surcharger l’installation électrique − s’assurer que l’alimen- tation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’APPAREIL peut blesser. N’utiliser que l’anneau de levage pour lever l’ap- pareil. NE PAS utiliser le chariot, les bouteilles de gaz ou tout autre accessoire. Utiliser un engin de capacité adéquate pour lever l’appareil. Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté op- posé de l’appareil. L’EMPLOI EXCESSIF peut FAIRESurchauffer L’Équipement.
Prévoir une période de refroidissement ; respec- ter le cycle opératoire nominal. Réduire le courant ou le cycle opératoire avant de reprendre le soudage. Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.Les
Charges
Électrostati-
QUES peuvent endommager les cir- cuits imprimés. Mettre un bracelet antistatique AVANT de mani- puler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimés. LES PIÈCES MOBILES peuvent cau- ser des blessures. Se tenir à l’écart des pièces mobiles. Se tenir à l’écart des points de coincement tels que les dévidoirs. LES FILS DE SOUDAGE peuvent cau- ser des blessures. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Ne pas diriger le pistolet vers soi, vers d’autres personnes ou vers toute pièce mécanique en en- gageant le fil de soudage. LES ORGANES MOBILES peuvent causer des blessures. Se tenir à l’écart des organes mobiles comme les ventilateurs. Maintenir fermés et bien fixés les portes, panneaux, recouvrements et dispositifs de protection.Le Rayonnement Haute Fré-
QUENCE (H. F.) risque de causer des interférences. Le rayonnement haute fréquence peut causer des interférences avec les équipements de radio- navigation et de communication, les services de sécurité et les ordinateurs. Ne demander qu’à des personnes qualifiées familiarisées avec les équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences causées par l’installation. Si la Federal Communications Commission signale des interféren- ces, arrêter immédiatement l’appareil. Faire régulièrement contrôler et entretenir l’installation. Maintenir soigneusement fermés les panneaux et les portes des sour- ces de haute fréquence, maintenir le jeu d’éclatement au réglage adéquat et utiliser une terre et un blindage pour réduire les interféren- ces éventuelles. LE SOUDAGE À L’ARC peut causer des interférences. L’énergie électromagnétique peut causer des interférences avec l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit compati- ble au point de vue électromagnétique. Pour réduire la possibilité d’interférence, maintenir les câbles de sou- dage aussi courts que possible, les grouper, et les poser aussi bas que possible (par ex. : à terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que le poste de soudage soit posé et mis à la terre confor- mément au présent manuel. En cas d’interférences après exécution des directives précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires tel- les que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. Porteurs de stimulateur cardiaque, restez à dis- tance. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’appro- cher des opérations de soudage à l’arc, de gou- geage ou de soudage par points.
OM-1327 Page 8 2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web : www.cganet.com). Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca- nadian Standards Association, Standards Sales, 178 boulevard Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- tional.org). Practice For Occupational And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site Web : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, norme NFPA 51B, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé- phone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org). OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de l’U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site Web : www.osha.gov). 2-5. Information sur les champs électromagnétiques Données sur le soudage électrique et les effets des champs magnéti- ques basse fréquence sur l’organisme En parcourant les câbles de soudage, le courant crée des champs élec- tromagnétiques. Les effets potentiels de tels champs restent préoccupants. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du National Research Council a conclu : « L’accumula- tion de preuves n’a pas démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ». Toutefois, les études et l’examen des preuves se poursuivent. En attendant les conclusions finales de la re- cherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le coupage. Afin de réduire les champs électromagnétiques en milieu de travail, res- pecter les consignes suivantes :
OM-1327 Page 9
Section 3 − Installation
3-1. Specifications Rated Output Max. Open Circuit 60 Hz Amps Input at Rated Output Rated Output Circuit Voltage 60 Hz200 V
230 V
460 V
575V
Kva
Kw
300 A at32 Vdc,
60% Duty 350 A at32 Vdc,
40% Duty 90 Single-Phase 69 (1.7*) 61 (1.5*) 30 (0.75*) 24 (0.5*) 13.1 11.2 60% Duty Cycle 40% Duty Cycle Three-Phase 34 (1.7*) 30 (1.5*) 15 (0.75*) 12 (0.5*) 11.6 11.550−700 Ipm
(1 3 17 8 m/min) H: 34 in (864 mm) W: 19 in (483 mm) 181 lb (82 kg) .023 − .045 in (0.8 − 1.1 mm) .030 − .045 in (0.8 − 1.1 mm) .035 − .047 in (0.9 − 1.2 mm) (1.3−17.8 m/min) W: 19 in (483 mm) D: 41 in (1041 mm) (82 kg) Operating Temperature Range: −20C to +40C Storage Temperature Range: -30C to + 50C 3-2. Duty Cycle And Overheating 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermistors open, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. Exceeding duty cycle can damage unit and void warranty. Overheating 0 15 A or VOr
Reduce Duty Cycle Minutes 60% Duty Cycle At 300 Amperes 40% Duty Cycle At 350 Amperes sduty1 5/95 / 217 442-A 4 Minutes Welding 6 Minutes Resting 10 15 20 25 30 40 50 60 70 80 90 100 100 150 200 225 250 300 400 500% Duty Cycle
Welding Amperes
OM-1327 Page 10 3-3. Volt-Ampere Curve
217 443-A
1 Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capa- bilities of the welding power source. Curves of other settings fall be- tween the curves shown.Maxvolts
Minvolts
0 50 100 150 200 250 300 350 0 10 20 30 40 50 60 70 80 90Voltage
Amperage
3-4. Installing Work Clamp 1 Work Cable 2 Boot Route cable through front panel opening. Slide boot onto work cable. 3 Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Close door.803 540-B
Tools Needed: 3/4 in 3 2 1
OM-1327 Page 11 3-5. Installing Welding Gun/Cable Holder 1 Welding Gun/Cable Holder 2 Wrapper 3 Slots Angle holder to insert hook through bottom slot. Drop holder down so that hook exits top slot. Ref. 803 545-A / Ref. 803 539-A 1 2 3 3-6. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. Ref. 803 541-A 1 3 4 2
OM-1327 Page 12 3-7. Connecting Spoolmatic 15A Or 30A Gun
803 568-B
1 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 2 Weld Cable 3 Shielding Gas Hose Route weld cable and gas hose through opening in front panel. 4 Positive Weld Output Terminal Connect weld cable to weld output terminal. 5 Regulator/Flowmeter Route shielding gas hose through wire drive compartment, out opening in rear panel, and up to regulator/flowmeter. Connect gas hose to regulator/flowmeter. Tools Needed: 3/4, 5/8 in 1 2 3 5 3 4 2
OM-1327 Page 13 3-8. Connecting XR Edge, XR-A Gun, Or XR-A Python 803 569-A / Ref. 803 570 -A / Ref. 803 463 1 Gun End 2 Gun Liner 3 Wire Outlet Guide Trim excess liner from end of gun so no more than 3/32 in (2.4 mm) of liner extends past wire outlet guide. 4 Gun Securing Knob Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob. Be sure to change drive rolls to the proper size and type. 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 1 5 4 3 2 3/32 in (2.4 mm) Be sure to trim liner to proper extension.
OM-1327 Page 14 3-9. Setting Gun Polarity For Wire Type 1 Polarity Changeover Information Always read and follow manufacture’s recommended polarity. 1 3/4, 11/16 in Ref. 803 541-A Changing Polarity Wire Drive Assembly Lead Work Clamp Lead Positive Terminal Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW). Negative Terminal Electrode Negative (DCEN): Reverse lead connections at terminals from that shown above for gasless flux core wires (FCAW). Drive assembly becomes negative.
OM-1327 Page 15 3-10. Installing Gas Supply
803 542-A
Tools Needed: 1-1/8, 5/8 in 1 2 3 4 5 7 Rear Panel 6 Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Regulator/Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator/flowmeter gas hose connection, and fitting on rear of welding power source. 7 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate. Argon Gas Or Mixed Gas Regulator/Flowmeter for 350P model shown. DO NOT use Argon/Mixed gas regulator/flowme- ter with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter. 3-11. Installing Wire Spool and Adjusting Hub Tension072573-B
When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. Tools Needed:
OM-1327 Page 16 3-12. Electrical Service Guide Single-Phase Three-Phase Input Voltage 200 230 460 575 200 230 460 575 Input Amperes At Rated Output 69 61 30 24 34 30 15 12 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Circuit Breaker 1, Time-Delay 2 80 70 35 25 40 35 15 10 Normal Operating 3 100 90 40 35 50 45 20 15 Min Input Conductor Size In AWG 6 8 10 12 10 10 14 14 Max Recommended Input Conductor Length In Feet (Meters) 101 (31) 86 (26) 229 (70) 217 (66) 86 26 114 35 178 54 277 85 Min Grounding Conductor Size In AWG 8 8 10 12 10 10 14 14 Reference: 1999 National Electrical Code (NEC) 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). Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. Caution: This unit is either a 200/230 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label.
OM-1327 Page 17 3-13. Selecting A Location And Connecting 3-Phase Input Power
803 543-B
Installation must meet all National and Local Codes - have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors form unit. Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. Caution: This unit is either a 200/230 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label. Disconnect Device Input Power Connections 1 Rating Label 2 Input Power Conductors 3 Line Disconnect Device 4 Disconnect Device (Supply) Grounding Terminal 5 Grounding Conductor Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. 6 Disconnect Device Line Terminals Connect input conductors L1, L2, and L3 to disconnect device line terminals. 7 Overcurrent Protection Select type and size of overcurrent protection using Section 3-12 (fused disconnect switch shown). Close and secure door on line disconnect device. Tools Needed: 2 = GND/PE Earth Ground 3 4 5 6 7 1 Rear Panel 18 in (457 mm) for airflow Do not move or operate unit where it could tip.
OM-1327 Page 18 3-14. Selection A Location And Connecting 1-Phase Input Power Ref. 803 543-B Tools Needed: 8 3 2 7 5 4 = GND/PE Earth Ground Installation must meet all National and Local Codes - have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors form unit. Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. Caution: This unit is either a 200/230 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label. Three Conductor Power Cord Preparation 1 Rating Label 2 Input Power Conductors 3 Black And White Input Conductors 4 Red Input Conductor 5 Insulation Sleeving 6 Grounding Conductor 7 Electrical Tape Insulate and isolate red conductor as shown. Disconnect Device Input Power Connections 8 Line Disconnect Device 9 Disconnect Device (Supply) Grounding Terminal Connect green or green/yellow grounding conductor (see Item 6) to disconnect device grounding terminal first. 10 Disconnect Device Line Terminals Connect input conductors L1 and L2 to disconnect device line terminals. 11 Overcurrent Protection Select type and size of overcurrent protection using Section 3-12 (fused disconnect switch shown). Close and secure door on line disconnect device. 6 2 9 6 10 11 1 Rear Panel 18 in (457 mm) for airflow Do not move or operate unit where it could tip.
OM-1327 Page 19 3-15. Threading Welding Wire For Roughneck Gun 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide 6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 6 in (150 mm) Hold wire tightly to keep it from unraveling.
Wood
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Close and tighten pressure assembly, and let go of wire. Remove gun nozzle and contact tip. Turn On. Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close and latch door.803 570-A / 803 544-A / S-0627-A
Tighten 1 2 3 4 Use pressure indi- cator scale to set a de- sired drive roll pres- sure. Pressure Indicator Scale Tighten 1 2 3 4 7 8 3 5 6 2 1 4
OM-1327 Page 20 3-16. Threading Welding Wire For XR Edge, XR-A Gun, Or XR-A Python 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide 6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 6 in (150 mm) Hold wire tightly to keep it from unraveling. Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Close and tighten pressure assembly, and let go of wire. See Section 3-17 for threading welding wire through XR guns. Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A Tighten 1 2 3 4 Use pressure indicator scale to set front drive roll pres- sure to 1 and rear drive roll pres- sure to less than 1. Pressure Indicator Scale
218243−A
Important!
For Aluminum Push−Pull welding. Thread hub tension nut looselyImportant!
For Aluminum Push−Pull welding. 1 2 3 4218244−A
7 8 3 5 6 2 1 4
OM-1327 Page 21 3-17. Threading Welding Wire Through XR Guns Ref. 802 193-A / 801 556 / Ref. 151 666-C Tools Needed: Welding wire is electrically live when gun trigger is used to jog wire. Refer to Section 3-16 for instruc- tions on feeding wire through welding power source. 1 Pressure Roll Assembly Lay gun cable out straight. Open top cover, and open pressure roll as- sembly. If not already done, remove gun barrel assembly. Press gun trigger until about 4 in (102 mm) of wire is sticking out front of gun. Insert wire into barrel liner and tighten barrel as- sembly. Install correct size contact tube and install collet nut. Close top cover on gun. Press trigger switch until about 6 in (152 mm) of wire is sticking out end of contact tip. Cut off wire. Close and latch door. XR Edge gun drive roll pressure should be set at minimum. Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Do not exceed midrange setting. Cut off wire. Close and latch door. Turn welding power source Off. Nonconductive Surface For XR-A Edge Gun: For XR-A Pistol Gun: For XR-A Pistol Gun: 1 Pressure Roll Assembly 2 Drive Roll 3 Thumbscrew Lay gun cable out straight. Open top cover, and lift pressure arm and open pressure roll assembly. If not already done, remove gun barrel assembly. Manually thread wire along drive roll groove. Close pressure roll assembly. Press gun trigger until about 4 in (102 mm) of wire is sticking out front of gun. Insert wire into barrel liner and tighten barrel as- sembly. Install correct size contact tube and install collet nut. Reinstall gun cover. 4 Pressure Adjustment Knob See final pressure adjustment at bottom of page. 1 2 Turn On Welding Power Source. Turn On Welding Power Source. 1 3 Remove barrel assembly before threading wire through gun. Remove barrel assembly before threading wire through gun.
OM-1327 Page 22
Section 4 − Operation
4-1. Controls 1 Pulse Indicator Light Pulse only lights if unit has the pulse MIG module and is programmed for pulse MIG. 2 MIG Indicator Lights Pulse (1) and MIG (2) illuminate to Indicate weld mode of unit. 3 Process Light PROCESS illuminates when unit is in Process select menu. 4 Wire Light WIRE illuminates when unit is in Pulse MIG program select menu. 5 Timers Light TIMERS illuminates when unit is in Timers menu. 6 Setup Button Use button to access Timers, Process and Wire menus. 7 Arc Control Button Use button to select either inductance control in MIG welding mode or Sharp Arc in Pulse MIG welding mode. 8 Left Knob Use knob to adjust volts in MIG welding mode or change parameter values in Setup. 9 Right Knob Use knob to adjust wire speed in MIG welding mode or change parameter values in Setup. 10 Left Display 11 Right Display 12 Weld Functions/Setup Indicator Lights VOLTS illuminates in MIG welding mode indicating volts in left display can be adjusted. Also, VOLTS lights to indicate left display is showing actual voltage during welding and for 5 seconds after the arc is extinguished. ARC LENGTH illuminates in Pulse MIG welding mode indicating Arc Length can be adjusted. SETUP illuminates when a parameter on the corresponding display above the light can be adjusted. WIRE SPEED illuminates in either Pulse MIG or MIG welding mode indicating wire speed can be adjusted. AMPS illuminates indicating welding amps appears in the display, instead of wire speed, during welding and for 5 seconds after the arc is extinguished. 1 11 Ref. 213 935-A 9 8 6 5 4 3 10 12 7 2 The first time the welding power source is energized it starts in MIG welding mode. Each time after the initial startup, when the unit is turned off, whatever mode and parameter settings were last set will remain as the current settings the next time the unit is energized.Note
4-2. MIG Mode In MIG mode, VOLTS is lit under left display and WIRE SPEED is lit under right display. Left knob is used to adjust welding voltage within a range of 14-32 volts, and right knob is used to adjust wire feed speed within a range of 25-700 IPM. Refer to weld chart in front compartment for proper parameter settings according to wire type, shielding gas, and material type and thickness.
OM-1327 Page 23 4-3. Jog Mode If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld power. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow because gas valve is located inside spool gun. For MIG guns, wire will feed for up to 2 minutes while trigger is pressed, then wire drive system in unit will automatically shut off. For spool guns, wire will feed for up to 30 seconds before shutting off. If gun trigger is pressed for 3 seconds without striking an arc the displays will show JOG MODE. 4-4. Weld Status When trigger is released on a MIG gun, spool gun, or push-pull gun, the last actual amperage and voltage will be shown on the displays for 5 seconds. The VOLTS and AMPS indicator lights will illuminate under the displays and each value will appear in the corresponding display. If a programmed value requires adjustment after the arc is extinguished and during the 5 seconds display of actual values, turning either knob will cause actual values in the displays to be replaced by programmed values for adjustment purposes. The 5 second delay after the arc is extinguished for displaying actual weld values can be turned on or off in the Timer menu DISP selection (see Section 5-3).
Note
4-5. MIG Gun-On-Demand The guns that can be used with this unit are MIG guns, spool guns, and push-pull guns. To switch from one gun to another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun. If the unit is powered down and back on again, the gun last used will become the current active gun. 4-6. Pulse MIG Mode Voltage Adjustment In Pulse MIG mode there is no manual voltage adjustment; instead, voltage is synergically aligned with the proper wire feed speed. Arc Length adjustment is used to adjust actual arc length which automatically adjusts the voltage. See weld chart in front compartment for proper wire feed speed adjustment according to wire size and type. 4-7. Pulse MIG Gun-On-Demand The spool gun functions slightly different in Pulse MIG mode. To switch from one gun to another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun. For a spool gun, the wire speed is taken from the position of the gun potentiometer. This wire speed value is automatically adjusted if the potentiometer is moved since the last time the gun was active. If the unit is powered down and back on again, the gun last used will become the current active gun. 4-8. Tip Saver If gun contact tip is directly shorted to the workpiece while gun trigger is pressed, the welding arc automatically shuts off after 1 second to prevent wire burnback in the contact tip.
OM-1327 Page 24 4-9. Weld Parameters For MIG And Pulse Mode Reference Volts/Wirefeed 23.5/220
OM-1327 Page 25
Section 5 − Programming
5-1. MIG Welding Mode When the MIG light (2) is illuminated, the unit is in MIG Welding mode.Setup
To enter MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select the gun being used. Select MIG for standard MIG gun, or select XR-A, EDGE, PYTH for push pull guns, or SPL for spoolgun. Depress SETUP (6) a second time to illuminate the PROCESS (3) light. Rotate right knob (9) until MIG is displayed (for MIG only units NOT USED will be displayed). Depress SETUP (6) button again to illuminate the WIRE (4) light. This menu is not used in MIG Welding mode. Depress SETUP (6) button again to illuminate TIMERS (5) light. For description of the TIMERS, refer to TIMERS menu (see Section 5-3) Depress SETUP (6) button again to exit menus and enter MIG welding mode.Operation
Adjust welding Voltage with left knob (8) and Wire Feed Speed with right knob (9). Refer to MIG welding chart for proper Voltage and Wire Feed Speed setting in reference to material type, material thickness, wire, and gas (see Section 4-9).Arc Control
MIG welding mode: Depress ARC CONTROL (7) button to enter Arc control menu and INDU will appear on the left display and the corresponding setting will appear on the right display. Adjust right knob (9) to adjust inductance setting. In MIG welding mode the Arc control is an inductance control from 0-99. Refer to MIG welding chart for suggested Inductance setting for the wire and gas types being used (see Section 4-9). Changing the inductance will change the fluidity of the puddle. Low Inductance High Inductance Weld Bead Weld Bead (0 setting) 99 setting Ref. 213 935-A 1 7 9 8 2 3 4 5 6
OM-1327 Page 26 5-2. Pulse MIG Welding Mode When the PULSE MIG (1, 2) is illuminated, the unit is in Pulse MIG Welding mode.
Setup
To enter Pulse MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select the gun being used. Select MIG for standard MIG gun, or select XR-A, EDGE, PYTH for push pull guns, or SPL for spoolgun. Depress SETUP (6) a second time to illuminate the PROCESS (3) light. Rotate right knob (9) until PULS is displayed. Depress SETUP (6) button again to illuminate the WIRE (4) light. Adjust left knob (8) to select wire type, adjust right knob (9) to select wire size. Depress SETUP (6) button again to exit WIRE menu and enter TIMERS (5) menu. The TIMERS (5) light will illuminate. For description of the TIMERS, refer to TIMERS menu (see Section 5-3) Depress SETUP (6) button again to exit menus and enter PULSE welding mode.Operation
Adjust right knob (9) for proper Wire Feed speed and adjust left knob (8) to change Arc Length if required. Arc length will de- fault to 50 if never adjusted previously. Re- fer to Pulse MIG welding chart for proper Wire Speed setting for metal and metal thickness being welded (see Section 4-9). All Pulse MIG programs are setup with the gases listed in the Pulse MIG welding chart. If alternate gases are used, adjust Arc Length and/or Sharp Arc (Arc Con- trol) (7) to adjust arc characteristics.Arc Length
Arc length can be adjusted from 0-99. All Pulse MIG programs are set with a value ofArc Control
Pulse MIG (1, 2) welding mode: Depress ARC CONTROL (7) button to enter Arc Control menu for sharp arc. SHRP will ap- pear on the left display and the correspond- ing setting will appear on the right display. The setting can be adjusted from 0-50 and all Pulse MIG welding programs are de- signed with a setting of 25. Adjusting the Sharp Arc setting will vary the width of the welding arc cone. (0 Setting) (50 Setting) Low Setting High Setting If a gas is used other than what is listed on the Pulse MIG welding program chart, the Sharp Arc can be adjusted to help custom- ize your arc to the gas being used. Ref. 213 935-A 1 7 9 8 2 3 4 5 6
OM-1327 Page 27 5-3. Timers To enter the TIMERS (5) menu depress the SETUP (6) button 4 times or until the TIMERS light (5) is illuminated. Items that can be adjusted in this menu are: Run-in speed (R-IN) − The speed of the wire prior to the welding arc being struck. This setting is a percentage of the Wire Feed Speed the unit is set to for welding. Programming value ranges from 25-150. Preflow (PRE) − The amount of time that the shielding gas will flow after the trigger is depressed and before the welding arc will be allowed to be active. Range of setting is from 0-5 seconds. Postflow (POST) − The amount of time that the shielding gas will flow after the arc has been shut off. Range of setting is 0-10 seconds. Spot/Stitch Timer (SPOT) − The amount of time that the arc will be active before it shuts off automatically. Range of setting is from 0-120 seconds. Spot timer is reset upon release of welding gun trigger. Display (DISP) − Allows the Wire Speed display to show actual welding amperage while arc is active and for 5 seconds after arc is shut off. Setting is either AMPS or WFS for standard Wire Feed Speed. Once in the TIMERS (5) menu, rotate the left knob (8) to find a particular item, and ro- tate the right knob (9) to change setting or status. Depress SETUP (6) button to get out of TIMERS (5) menu and to enter welding mode. Ref. 213 935-A 1 9 8 2 3 4 5 6 7
OM-1327 Page 28 5-4. Arc Times And Arc Starts Arc times and number of arc starts are saved in unit memory. To view this information, press both SETUP (1) and ARC CONTROL (2) buttons at the same time. Left display will initially show number of arc starts. Rotate right knob (8) and display will change to show arc hours. To exit this menu, press either the SETUP (1) or ARC CONTROL (2) button, or press a gun trigger on any welding gun con- nected to the unit. Ref. 213 935-A 3 1 2 Accessing the Arc Times and Arc Starts data will also allow access to Software Version data and Motor Calibration function. The software version data and motor calibration function are for use by factory authorized service personnel only. Do not use the motor calibration function if it appears on the displays.
OM-1327 Page 29 5-5. System Reset A system reset function is available that completely resets unit back to all the original factory settings. To access this menu, press and hold the SETUP (1) button, and turn on welding power source. SRST will appear on the left display and OFF will appear on the right display. To prepare the unit for system reset, rotate left knob until ON appears on the right display. To apply the system reset function, press SETUP (1) button, and wait until unit completely reboots before performing any other operations. Ref. 213 935-A 1 Accessing the System Reset function will also allow access to Timer Reset (RTMR) and Option Reset (ORST) functions. The timer reset and option reset functions are for use by factory authorized service personnel only. Do not use the timer reset or option reset functions if they appear on the displays.
OM-1327 Page 30
Section 6 − Maintenance &Troubleshooting
6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals Check gun cable. 6 Months Blow out or vacuum inside.Or
Clean drive rolls. 6-2. Overheating Thermistors RT1 and RT2 protect the unit from damage due to overheating. If output diode heatsink or IGBT heatsink gets too hot, RT1 and/or RT2 opens and output stops. The fan keeps running to cool the unit. Wait several minutes before trying to weld.
OM-1327 Page 31 6-3. Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Anti-Wear Guide Install guide as shown. 4 Intermediate Guide 5 Drive Roll The drive assembly comes equipped with factory installed .035/.045 combination drive rolls. Be sure that all 4 drive rolls are installed correctly. Combination drive rolls consist of two different sized grooves. The stamped markings on the end sur- face of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the carrier gear is the groove for the wire size viewed on the end surface of the drive roll. Install correct drive roll for wire size and type. 6 Drive Roll Securing Nut Turn nut one click to secure drive roll. 1 3 2 5 6 Tools Needed: 5/64 in 7/16 in
802 520-A
1 4 Stamped .035 Stamped .045 .045 Groove .035 Groove
OM-1327 Page 32 6-4. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-13 or 3-14). Replace building line fuse or reset circuit breaker if open (see Section 3-13 or 3-14). Secure gun trigger connections (see Section 3-6). Have Factory Authorized Service Agent check Power switch. Have Factory Authorized Service Agent check all board connections and main control board. No weld output; wire feeds. Thermistor RT1 or RT2 open (overheating). Allow fan to run; the unit will be enabled when it has cooled and temperatures are within acceptable limits (see Section 3-2 and 6-2). Connect work clamp to get good metal to metal contact. Replace contact tip (see gun Owner’s Manual). Have Factory Authorized Service Agent check main control board and main rectifier. Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 3-13 or 3-14). Have Factory Authorized Service Agent check main control board and user interface board. Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1). Change to correct size drive rolls (see Section 6-3). Readjust drive roll pressure (see Section 3-15). Replace inlet guide, contact tip, and/or liner if necessary (see gun Owner’s Manual). Have Factory Authorized Service Agent check input voltage. Have Factory Authorized Service Agent check main control board. No wire feed. Turn Wire Speed control to higher setting (see Section 4-1). Clear obstruction in gun contact tip or liner (see gun Owner’s Manual). Readjust drive roll pressure (see Section 3-15). Change to correct size drive rolls (see Section 6-3). Rethread welding wire (see Section 3-15). Check gun trigger and leads. Repair or replace gun if necessary. Have Factory Authorized Service Agent check main control board and user interface board. H − − message appears on voltmeter and ammeter displays to indicate thermistor RT1 or RT2 is open and unit is in an overheated condition (see Section 6-5).
OM-1327 Page 33 Notes
OM-1327 Page 34 6-5. Help Displays
A
V
A
V
A
V
Help
0A
V
A
V
A
V
A
V
A
V
A
V
A
V
Help
1Help
2Help
3Help
4A
V
Help
5A
V
Help
6Help
8Help
9Help
10Tip
Save
Mm
350P
A
V
Mm
350A
V
Jog Mode
A
V
Help
7A
V
Help
11
OM-1327 Page 35
Sc-187 212-A
All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 0 Indicates overheating on left side of unit (displays flash between OVER TEMP and HELP 1). Unit will shutdown until internal temperature drops within operational range. Help 1 Indicates communication lost between control board PC1 and user interface board. Help 2 Indicates overheating on right side of unit (displays flash between OVER TEMP and HELP 2). Unit will shutdown until internal temperature drops within operational range. Help 3 Indicates no open circuit voltage detected when gun trigger is pulled and no arc detected within 3 seconds. If this display is shown, turn off primary input power and contact a Factory Authorized Service Agent. Help 4 Indicates gun trigger was pulled and held for 2 minutes without a welding arc established or there is a direct short between contact tip or wire and the workpiece. Release gun trigger and clear fault condition. Help 5 Indicates a malfunction in wire feed system and/or drive motor overcurrent condition. Check for proper spool brake adjustment or obstructions in wire feed system. Clean or replace liner, wire guides, or contact tip. Help 6 Indicates a malfunction in wire feed system and/or external drive motor overcurrent con- dition (spool gun or push-pull gun). Check for proper spool brake adjustment or obstructions in wire feed system. Clean or replace liner, wire guides, or contact tip. Help 7 Indicates input voltage malfunction (voltage too high or too low) causing unit to automatically shut down. Turn off input primary power and check input voltage per primary voltage rating of welder. Unit will operate once input voltage is within specification and power to unit is turned off and back on. Help 8 Indicates a malfunction in the secondary power circuit of the unit. Check control board PC1, and primary and secondary connections. Help 9 Indicates a malfunction in Pulse MIG function. Check connection between pulse board and user interface board. Replace pulse board, if necessary. Help 10 Indicates a trigger error when two gun triggers are activated at the same time. Release gun triggers to clear error. Help 11 Indicates a tach error when tach feedback signal is not present. Release and press gun trigger to reset tach signal. If error continues, contact a Factory Authorized Service Agent. Tip Save Indicates contact tip is directly shorted to workpiece. Arc shuts off in this condition, and message resets when tip is not touching workpiece and gun trigger is released.Mm 350P
When unit is turned on, this display indicates that pulse option is installed and operational.Mm 350
When unit is turned on, this display indicates that unit is either a MIG only machine or pulse option is installed but not operational. Jog Mode Indicates trigger is pressed, but no arc is detected. Wire feed speed goes to Jog mode speed after 3 seconds.
OM-1327 Page 36
Section 7 − Electrical Diagram
Figure 7-1. Circuit Diagram
OM-1327 Page 37
212 985-G
OM-1327 Page 38
Section 8 − Parts List
803 545-A
Hardware is common and not available unless listed. 1 2 3 5 6 7 9 13 12 16 17 18 19 20 21 22 23 24 25 4 27 28 15 14 8 − Fig 8-2 10 − Fig 8-3 11 − Fig 8-5 26 − Fig 8-4 Figure 8-1. Main Assembly
OM-1327 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 212829
Door,Access Wire Compartment
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Neg
097416Terminal,Pwr Output Black
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Pos
097421Terminal,Pwr Output Red
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C6,7
213038Capacitor Assy
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Hd1
189567Transducer,Current 400A Module Supply V +/− 15V
1 . . . . . . . . . . . . . . . . . . . . 183046Cable,Lem
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 221326Bus Bar,Current Sensor
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 199824Label,Warning Electic Shock And Pinch Points
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fig 8-2Baffle,Center
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 212821Panel,Front Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fig 8-3Inverter Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 +Fig 8-5Panel,Rear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 134464Label,Warning General Precautionary Static&Wire
1 . . . . . . . . . . . . . . . . . . . . . . . 13 212826Door,Access Tool Compartment
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 217829Latch,Door Straight Loop Catch
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 215061Gun/Cable Holder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 +212823Wrapper
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 213939Label,Warning Electric Shock Can Kill Significant
1 . . . . . . . . . . . . . . . . . . . . . . . . 18 186758Wheel,Polypropylene 10 In X 2.25 Wide
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 602250Washer,Flat .812Idx1.469Odx.134T Stl Pld Ansi.750
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 121614Ring,Rtng Ext .750 Shaft X .085 Thk E Style Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 213903Rack,Cylinder Single
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 212833Base,
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 209870Caster,Swvl 4.00 In X 1.250 In Poly−Olefin
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Fm
213043Fan,Muffin 24Vdc 3000 Rpm W/20.500 In Leads
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 212846Bezel,Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fig 8-4Panel,Front
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 212822Panel,Side Lh Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 151187Latch,Slide Flush Mtg Hole 1.000 Widex 1.500 Lg
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194755Roughneck C−4012 Gun
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209123Regulator/Flowmeter,10−50 Cfh Argon/Mix (350 Model)
1 . . . . . . . . . . . . . . . . . . . . . . . 210925Regulator/Flowmeter,0−50 Cfh Ar/Co2
. . . . . . . . . . . . . . . . . .W/Flowtube(350P Model)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144108Hose,Gas 5Ft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196329Cable,Work 10 Ft No1 W/Clamp & Boot
. . . . . . . . . . . . . . . . . .(350 Model) (Including)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130750Clamp,Work 300 Amp
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196318Cover,Cable Btry Post Blk .75 Id
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213369Cable,Work 10 Ft 1/O W/Clamp & Boot
. . . . . . . . . . . . . . . . . .(350P Model) (Including)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213619Clamp,Work 300 Amp Stl Chrome Pld W/Cop Contacts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 196318Cover,Cable Btry Post Blk .75 Id
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206186Tip,Fastip .312 Od .035 And .030Al Wires
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206188Tip,Fastip .312 Od .045 And .040Al Wires
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220524Module, Tach (350 Model Only)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦212492Regulator/Flowmeter, 0−50 Cfh Co2
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-1327 Page 40
803 546-A
Hardware is common and not available unless listed. 1 3 2 4 5 6 7 8 9 10 12 13 14 15 16 13 17 11 Figure 8-2. Baffle, Center w/Components Description Part No. Dia. Mkgs. Item No. Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7) Quantity 1 058427Ring,Retaining Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 085980Nut,Stl Hex Full .625-11
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 605941Washer,Flat Stl .640 Id X 1.000 Od X 14Ga Thk
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 186437Spring,Cprsn .845 Od X .110 Wire X 1.500
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 057971Washer,Flat Stl Keyed 1.500Dia X .125Thk
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 057745Spring,Cprsn 2.305 Od X .090 Wire X 2.500 Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 186435Hub,Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 186436Washer,Brake Plastic
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 198425Cap,Finishing 1.19 X .37
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 198426Washer,Cap
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 212824Baffle,Center
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 177307Reel Support
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 134201Stand−Off Support,Pc Card .312/.375W/Post&Lock .43
10 . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7) (Continued) Quantity 14
Pc1
220522Circuit Card Assy,Control W/Program
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg7
115092Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg8
131056Housing Rcpt+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg10,14 115091
Housing Plug+Skts,(Service Kit)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg11,17 131054
Housing Plug+Skts,(Service Kit)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg12,13,
. . . . . . 27 131204Housing Plug+Skts,(Service Kit)
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg16,
. . . . . . .Plg27
131204Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213404Cable,Interconnecting Rs 485 Interface To Control
1 . . . . . . . . . . . . . . . . . . . . . . . . . 213405Cable,Interconnecting Rs 485 Interface To Pulse Op
1 . . . . . . . . . . . . . . . . . . . . . . . . . 168674Cable,Ribbon 24 Posn 14.000 In Skts Be Inverted
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pc6
216342Circuit Card Assy,Gmaw Pulse W/Program
. . . . . . . . .(Pulse Model Only)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg29
131204Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg30
115091Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 212843Housing,Adapter Drive Motor
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fig 8-6Drive Assy,Wire 4 Roll
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-1327 Page 42
803 552-A
Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 11 13 14 15 17 20 19 18 21 22 23 24 25 16 26 27 28 29 30 31 32 12 10 Figure 8-3. Inverter Assy Description Part No. Dia. Mkgs. Item No. Figure 8-3. Inverter Assy (Fig 8-1 Item 9) Quantity 1W
188634Contactor,Def Prp 60A 3P 24Vac Coil W/Cover
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .C11,12,
. . . . . . . 13 148240Capacitor,Cer Disc .003 Uf 2000 Vac W/Terms
3 . . . . . . . . . . . . . . . . . . . . . . 2 +212750Windtunnel,Lh
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185835Label,Warning Electric Shock/Exploding Parts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3T1
180952Xfmr,Hf
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L1
216006Inductor,Input
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Z1
212756Stabilizer,Output
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Sr1
212937Kit,Diode Power Module
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7T2
213022Xfmr,Control 200/230 Pri 48Ct/36Ct/16.7/20.0 Sec
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 7T2
213024Xfmr,Control 460/575 Pri 48Ct/36Ct/16.7/20.0 Sec
1 . . . . . . . . . . . . . . . . . . . . . . . . . .Plg26
168071Housing Plug Pins+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 +212752Windtunnel,Rh
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Cr1
106462Relay,Encl 24Vdc Dpdt 20A/120Vac 8Pin Flange Mtg
1 . . . . . . . . . . . . . . . . . . . . . 10 177547Bushing,Snap−In Nyl Ct−Mount 1.125 Mtg Hole
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Ct1
213032Xfmr,Current
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 025248Stand−Off,Insul .250−20 X 1.250 Lg X .437 Thd
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C1
186015Capacitor,Polyp Film .34 Uf 1000 Vac +8% −0%
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14C3,4
192935Capacitor,Elctlt 2700 Uf 450 Vdc Can 2.52 Dia
. . . . . . . . .(200/230 Models)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14C3,4
193738Capacitor,Elctlt 1800 Uf 500 Vdc Can 2.52 Dia
. . . . . . . . .(460/575 Models)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pc2
211125Circuit Card Assy,Interconnect (200/230)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pc2
219900Circuit Card Assy,Interconnect (460/575)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg2
168071Housing Plug Pins+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 185835Label,Warning Electric Shock/Exploding Parts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 175140Bracket,Di−Dt
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178591Label,Connection Di/Dt
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 181197Gasket,Di−Dt Rubber
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 43 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Inverter Assy (Fig 8-1 Item 9) (Continued) Quantity 19
L3,4
175482Coil,Di/Dt
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 109056Core,Ferrite E 2.164 Lg X 1.094 High X .826 Wide
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Pm1,2
212936Kit,Transistor Igbt Module
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Rt2
213029Thermistor,Ntc 30K Ohm @ 25 Deg C 26In Lead 3P
1 . . . . . . . . . . . . . . . . . . . . . . . . 23 212776Heat Sink,Power Module
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 212753Heat Sink,Rect
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 175255Insulator,Rectifier
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 214537Cover,Access Fan Motor
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 181853Insulator,Screw
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28C2,R1,C5 175194
Resistor/Capacitor,
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Rt1
213028Thermistor,Ntc 30K Ohm @ 25 Deg C 26In Lead 2P
1 . . . . . . . . . . . . . . . . . . . . . . . . 30D1,2
201531Kit,Diode Power Module
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 199840Bus Bar,Diode
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 179276Bushing,Snap−In Nyl 1.000 Id X 1.375 Mtg Hole Cent
2 . . . . . . . . . . . . . . . . . . . . . . . . . . +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-1327 Page 44 Hardware is common and not available unless listed.
803 547-A
1 2 3 4 5 6 7 8 9 10 11 13 12 14 Figure 8-4. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 8-4. Panel, Front w/Components (Fig 8-1 Item 23) Quantity 1 212837Handle,
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212845Bezel,Upper
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 212819Panel,Front
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 212825Enclosure,Circuit Card Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C8
200953Module,Filter .1Mf 500Vdc 10 Ckt
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 048282Rcpt W/Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C9,10
080894Capacitor,Cer Disc .01 Uf 1000 Vdc 20% Nylez
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 190363Rcpt W/Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S1
128756Switch,Tgl 3Pst 40A 600Vac Scr Term Wide Tgl
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 9Pc3
212979Circuit Card Assy,User Interface
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg18
115094Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg19
135560Housing Rcpt+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg28
131055Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 213936Label,Power/Mig Gun/Spoolgun
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 212847Bezel,Door
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218551Instruction,Flipchart
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215232Clip,Component .580H X .715W Adh Back
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213934Label,Nameplate Mm350
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213935Label,Nameplate Mm350P
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 212955Label,Controls User Interface
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 213134Knob,Encoder 1.670 Dia X .250 Id Push On W/Spring
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 210398Bushing,Snap−In
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-1327 Page 45
803 549-A
Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 Figure 8-5. Panel, Rear w/Components Description Part No. Dia. Mkgs. Item No. Figure 8-5. Panel, Rear w/Components (Fig 8-1 Item 10) Quantity 1 212820Panel,Rear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 169654Bracket,Support Tank
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 200285Label,Warning Cylinder May Explode If Damaged
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 188441Chain,Weldless 2/0 X 31. Bright Zinc Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 137761Nut, 750Npt 1.31Hex .27H Nyl Blk
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Gs1
216395Valve, 34Vdc 2Way Custom Port 1/8 Orf W/Frict
1 . . . . . . . . . . . . . . . . . . . . . . . . . 7 010467Conn,Clamp Cable 1.250
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 212772Cable,Power 10 Ft 6In 6Ga 4C (200/230V)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦213 380Plug,Str Grd 2P3W 50A 250Vac *6−50P
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 213018Cable,Power 10 Ft 6 In 10Ga 4C (460/575V)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213908Plate,Adapter Power Cord (575 Model Only)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 214654Label,Warning Electric Shock/Input Power
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .♦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-1327 Page 46 Ref. 803 548-A Hardware is common and not available unless listed. Figure 8-6. Wire Drive Assembly See Table 8-1 Drive Roll & Wire Guide Kits. 1 17 19 20 25 18 20 19 2 16 15 5 26 9 10 11 12 13 27 3 34 35 24 22 23 26 27 28 30 31 32 33 29 28 27 21 19 20 26 14 28 38 37 36 39 27 26 6 7 8 9 10 11 12 13 4 Description Part No. Dia. Mkgs. 213137 Item No. Figure 8-6. Wire Drive Assembly Quantity 1 216409
Motor,Gear 24Vdc 150Rpm 24:1 Ratio W/Tach
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212844Insulator,Drive Housing 4 Roll
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 166337Housing,Adapter Gun/Feeder (Salable As 046621)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 194521Insulator,Drive Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 166071Lever,Mtg Pressure Gear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 166338Lever,Mtg Pressure Gear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 079634Pin,Hinge
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 151828Pin,Cotter Hair .042 X .750
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 085242Fastener,Pinned
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 085244Washer,Cupped .328Idx .812Odx16Gax.125 Lip
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 196896Cup,Spring
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 196897Spring,Cprsn .695 Od X .095 Wire X 1.500
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 196895Knob,Tension
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 010224Pin,Spring Cs .187 X 1.000
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 079633Ftg,Hose Brs Barbed Nipple 3/16 Tbg
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 195640Screw,M 6−1.0X 16 Flathd−Phl Stl Pld
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 079240Screw,375−16X1.75 Hex Hd−Pln Stl Pld Full Thrd
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 601966Screw,375−16X1.25 Hex Hd−Pln Gr5 Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 602213Washer,Lock .380Idx0.691Odx.115T Stl Pld Split.375
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 602242Washer,Flat .375Idx0.875Odx.083T Stl Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 601872Nut, 375−16 .56Hex .34H Stl Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 108943Screw,250−20X1.50 Hexwhd.61D Gr5 Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 221 654Washer,Shldr Insulating
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 47 Description Part No. Dia. Mkgs. 213137 Item No. Figure 8-6. Wire Drive Assembly (Continued) Quantity 24 089800
Nut, 250−20 .44Hex .22H Stl Pld .58D Flange Defor
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 602154Screw,250−20X .50 Hexwhd.50D Stl Pld Slffmg Tap−Rw
2 . . . . . . . . . . . . . . . . . . . . . . . 26 166072Spacer,Gear
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 172075Carrier,Drive Roll W/Components 24 Pitch
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 602009Screw,250−20X1.25 Soc Hd−Hex Gr8 Pln
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 173618Carrier,Drive Roll 10Mm Shaft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 195802Washer,Flat .175Idx0.590Odx.040T Stl Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 602241Washer,Flat .281Idx0.625Odx.065T Stl Pld Ansi.250
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 174609Screw,M 4− .7X 12 Cheese Hd Blk Din 84
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 604538Washer,Flat .344Idx0.688Odx.065T Stl Pld Ansi.312
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 204585Knob,Fluted 1.75 In W/ .312−18 Stud 1.00 Lg
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 045127Guide,Wire Inlet Anti−Wear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 602169Screw,Set # 8−32X .18 Cup Pt Sch Stl Pln
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 056193Guide,Wire Inlet
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 056207Guide,Wire Intermediate
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 189285Roll,Drive V Groove .035−.045 Wire
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. Table 8-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 V-Knurled rolls for hard shelled cored wires. 4 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Wire Diameter Fraction Decimal Metric .023/.025 in .030 in .035 in .045 in .052 in 1/16 in .035 in .045 in .052 in 1/16 in .035 in .045 in .052 in 1/16 in .023/.025 in .030 in .035 in .045 in .052 in .062 in .035 in .045 in .052 in .062 in .035 in .045 in .052 in .062 in 0.6 mm 0.8 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm Kit No. 087 132 046 780 046 781 046 782 046 783 046 784 044 750 046 785 046 786 046 787 046 792 046 793 046 794 046 795 Drive Roll Part No. Type 087 130 053 695 053 700 053 697 053 698 053 699 072 000 053 701 053 702 053 706 132 958 132 957 132 956 132 955 V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved U-Grooved U-Grooved U-Grooved U-Grooved V-Knurled V-Knurled V-Knurled V-Knurled Wire Guide Inlet Intermediate 056 192 056 192 056 192 056 193 056 193 056 195 056 192 056 193 056 193 056 195 056 192 056 193 056 193 056 195 056 206 056 206 056 206 056 207 056 207 056 209 056 206 056 207 056 207 056 209 056 206 056 207 056 207 056 209 Ref. S-0025-D
OM-1327 Page 48 Item Number 1 2 3 4 5,7 Figure 8-7. Consumables Flowchart
OM-1327 Page 49 Description Part No. Item No. Figure 8-7. Consumables Flowchart Quantity Table 8-2. Nozzles 1 ♦176238 NOZZLE, spot flat (requires diffuser 209099, used with any . . . . . . . . . . . . . . heavy duty FasTip contact tip) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦176240 NOZZLE, spot inside corner (requires diffuser 209099, used with any . . . . . . . . . . . . . . heavy duty FasTip contact tip) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦176242 NOZZLE, spot outside corner (requires diffuser 209099, used with any . . . . . . . . . . . . . . heavy duty FasTip contact tip) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 610 NOZZLE, screw on brass 1/2 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 611 NOZZLE, screw on brass 3/4 in orifice straight 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 612 NOZZLE, screw on brass 3/4 in orifice straight heavy duty 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 613 NOZZLE, screw on brass 5/8 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 614 NOZZLE, screw on brass 5/8 in orifice heavy duty 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 615 NOZZLE, screw on copper 1/2 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 616 NOZZLE, screw on copper 3/4 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 617 NOZZLE, screw on copper 3/4 in orifice heavy duty 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 198 855 NOZZLE, screw on copper 5/8 in orifice (standard on 300 & 400 . . . . . . . . . . . . . . . amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 199 618 NOZZLE, screw on copper 5/8 in orifice heavy duty . . . . . . . . . . . . . . . (standard on 500 & 600 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦207 313 NOZZLE, screw on copper 5/8 in orifice 15/16 OD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦209 033 NOZZLE, slip on copper 1/2 in orifice tapered (requires diffuser 209031 or . . . . . . . . . . . . . 209032 and insulator 209047, used with any tapered FasTip contact tip) 1 . . 1 ♦209 034 NOZZLE, slip on copper 3/8 in orifice tapered (requires diffuser 209031 or . . . . . . . . . . . . . 209032 and insulator 209047, used with any tapered FasTip contact tip) 1 . . 1 ♦209 035 NOZZLE, screw on copper 3/8 in orifice tapered (requires diffuser 206195, . . . . . . . . . . . . . 206196 or 210664, used with any tapered FasTip contact tip) 1 . . . . . . . . . . . 1 ♦209 036 NOZZLE, screw on copper 1/2 in orifice tapered (requires diffuser 206195, . . . . . . . . . . . . . 206196 or 210664, used with any tapered FasTip contact tip) 1 . . . . . . . . . . . Table 8-3. Heavy Duty FasTipContact Tips* 2 ♦206 184 .023 in (0.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 185 .030 in (0.8 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 186 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 187 .040 in (1.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 206 188 .045 in (1.2 mm) (standard on 300 & 400 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 189 .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 206 190 1/16 in (1.6 mm) (standard on 500 & 600 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 191 .068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 192 5/64 in (2.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 193 3/32 in (2.4 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-4. Extra Heavy Duty FasTipContact Tips* 2 ♦199 605 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 606 .040 in (1.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 851 .045 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 852 .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 853 1/16 in (1.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 854 .068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 607 5/64 in (2.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 608 3/32 in (2.4 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 609 7/64−1/8 in (2.8 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 50 Description Part No. Item No. Figure 8-7. Consumables Flowchart (Continued) Quantity Table 8-5. Tapered FasTip Contact Tips* 2 ♦209024 .023 in (0.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209025 .030 in (0.8 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209026 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209027 .045 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209028 3/64 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209029 .052 in (1.3 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209030 1/16 in (1.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-6. Value Multi−Turn Contact Tips* 2 ♦087 300 .023 in (0.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦071 825 .030 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦054 202 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦054 201 .045 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 593 .3/64 in (1.2 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦044 006 .052 in (1.3 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦047 566 1/16 in (1.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦202 933 1/16 in (1.6 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 594 .068 in (1.7 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦047 565 5/64 in (2.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-7. Gas Diffusers 3 ♦198 857 1/8 in tip recess − for extra heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦199 623 Flush tip − for extra heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦199 621 1/8 in tip recess − for value multi−turn contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦199 622 Flush tip − for value multi−turn contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 206 195 1/8 in tip recess − for heavy duty FasTip contact tips . . . . . . . . . . . . . . . (standard on all guns) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦210 664 1/4 in tip recess − for heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦206 196 Flush tip − for heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦209 031 Slip on recessed diffuser (requires nozzle 209033 or 209034 . . . . . . . . . . . . . and insulator 209047, used with any tapered FasTip contact tip) 1 . . . . . . . . . . 3 ♦209 032 Slip on flush diffuser (requires nozzle 209033 or 209034 . . . . . . . . . . . . . and insulator 209047, used with any tapered FasTip contact tip) 1 . . . . . . . . . . 3 ♦209 099 Spot diffuser (requires spot nozzle 176238 or176240 or 176242) 1 . . . . . . . . . . . . . . . . . . . . . . . Table 8-8. Insulators 4 198 856 INSULATOR, Rubber 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 209 047 INSULATOR, Teflon (required when using diffuser 209031 or 209032 . . . . . . . . . . . . . . . with nozzle 209033 or 209034) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 202 292 COVER, nut 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-9. Liners 6 ♦202 889 LINER, monocoil .023−.030 wire x 16.5 ft round wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 202 890 LINER, monocoil .035−.045 wire x 16.5 ft round wound . . . . . . . . . . . . . . . (standard on 300 & 400 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 202 891 LINER, monocoil .052−1/16 wire x 16.5 ft round wound . . . . . . . . . . . . . . . (standard on 500 & 600 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 892 LINER, monocoil 1/16−.078 wire x 16.5 ft flat wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 893 LINER, monocoil 5/64−3/32 wire x 16.5 ft flat wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 894 LINER, monocoil 7/64−1/8 wire x 16.5 ft flat wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 895 LINER, monocoil 3/64−1/16 AL wire x 16.5 ft 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 51 Description Part No. Item No. Figure 8-7. Consumables Flowchart (Continued) Quantity Table 8-10. Goosenecks 7 +199 625 GOOSENECK, jacketed 4.5 in/50deg wrench swivel . . . . . . . . . . . . . (standard on 300 & 400 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 +199 626 GOOSENECK, jacketed 6 in/50deg wrench swivel . . . . . . . . . . . . . (standard on 500 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 +199 627 GOOSENECK, jacketed 8 in/50deg wrench swivel . . . . . . . . . . . . . (standard on 600 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 +♦213 450 GOOSENECK, jacketed 6.0” straight 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦Optional
+Includes nozzle insulator 198 856 and threaded nut cover 202 292. *All contact tips are packaged in bags of 25.Be Sure To Provide Model When Ordering Replacement Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model is required when ordering parts from your local distributor. Standard Consumables Chart Contact Tip 206 188 Nozzle 198 855 Diffuser 206 195 Liner 202 890 Gooseneck 199 625
OM-1327 Page 52
802 630-C
1 2 3 4 6 7 5 8 10 9 11 12 13 14 15 8 16 For consumable items 1 thru 7 see Figure 8-7. Figure 8-8. 4012 Gun
OM-1327 Page 53 Description Part No. Item No. Figure 8-8. 4012 Gun Quantity 8 199 630 HANDLE KIT, 300 & 400 amp models (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 632 SCREW, M4 x 18 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 633
Nut, M4
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 634 SCREW, M3 x 11 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 635Nut, M3
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 647 LABEL, gun handle Miller Roughneck 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 199 631 HANDLE KIT, 500 & 600 amp models (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 632 SCREW, M4 x 18 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 633Nut, M4
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 647 LABEL, gun handle Miller Roughneck 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 199 652 LABEL, back-end C-4012 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 199 637 SCREW, machine binding head 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 199 640 ADAPTER, Miller power pin (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 079 974 O-RING, Miller power pin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 079 878 HOUSING, plug and pins (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 531 CONN, circ cpc clamp str rlf size 11 .453 OD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ♦199 661 SWITCH, locking trigger 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 199 628 SWITCH, trigger (standard on all guns) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 199 629 SWITCH, contact pin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦199 662 HOOK, gun 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦199 663 KIT, adapter Miller to old Hobart/Thermal/Tweco (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 916 ADAPTER, Roughneck to old Hobart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 727 CONTROL LEADS, Hobart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦199 664 KIT, adapter Miller to Lincoln (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 918 ADAPTER, Roughneck to Lincoln 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 728 CONTROL LEADS, Lincoln 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .♦Optional
Be Sure To Provide Model When Ordering Replacement Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model is required when ordering parts from your local distributor.
Warranty Questions? Call
1-800-4-A-Miller
for your local Miller distributor. miller_warr 3/04 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. Effective January 1, 2004 (Equipment with a serial number preface of “LE” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.This Warranty Is Expressly In Lieu Of All Other
Warranties, Express Or Implied, Including The
Warranties Of Merchantability And Fitness.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.Miller Products Are Intended For Purchase And
Use
By
Commercial/Industrial
Users
And
Persons Trained And Experienced In The Use And
Maintenance Of Welding Equipment.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.To The Extent Permitted By Law, The Remedies
Provided Herein Are The Sole And Exclusive
Remedies. In No Event Shall Miller Be Liable For
Direct,
Indirect,
Special,
Incidental
Or
Consequential Damages (Including Loss Of
Profit), Whether Based On Contract, Tort Or
Any Other Legal Theory.
Any Express Warranty Not Provided Herein And
Any
Implied
Warranty,
Guaranty
Or
Representation As To Performance, And Any
Remedy For Breach Of Contract Tort Or Any
Other Legal Theory Which, But For This
Provision, Might Arise By Implication, Operation
Of Law, Custom Of Trade Or Course Of Dealing,
Including
Any
Implied
Warranty
Of
Merchantability Or Fitness For Particular
Purpose, With Respect To Any And All Equipment
Furnished By Miller Is Excluded And Disclaimed
By Miller.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.