Ask AI
— answers from the official manualAI-powered answers from the official manual. Verify critical info.
Common questions
Common Questions
56 totalHow do I enable the 14-pin remote control for stick (SMAW) welding?
The 14-pin remote control receptacle is factory-set to be active in TIG mode only. To enable it for stick welding, remove the power source cover and move DIP switch #2 to the upper position (stick remote enabled). Reinstall the cover after making the change. Always turn off the machine and verify capacitor voltage before opening the unit. (Page 16)
Where can I find the diagnostic fault codes for the PipeWorx 400 and wire feeder?
Diagnostic codes for the welding power source and wire feeder are covered in Section 7-10 of the manual. Additional troubleshooting information for the power source and wire feeder is found in Sections 7-11, 7-12, and 7-13. (Page 78)
How do I restore the factory settings on the PipeWorx 400?
The procedure for restoring factory settings is described in Section 7-3 of the manual. This section is located within the Maintenance and Troubleshooting chapter starting on page 72. (Page 72)
What input voltage options are available for the PipeWorx 400, and how do I change the voltage selection?
The PipeWorx 400 is available in 230/460V and 575V models. For the 230/460V model, you change the voltage selection by moving the reconnect board PC10 and plugging connector PLG4 into either receptacle RC8 (230V) or RC7 (460V). Make sure to reinstall all four mounting screws on the reconnect board after making the change. (Page 22)
What type of coolant is recommended for the PipeWorx 400 cooler, and what happens if I use a different coolant?
Use only low-conductivity coolant part number 043810, which protects down to -37°F (-38°C) and resists algae growth. Do not use a conductive coolant. Using any coolant other than those recommended voids the warranty on all parts in contact with the coolant, including the pump and radiator. (Page 12)
What is the maximum wire diameter supported by the PipeWorx 400 wire feeder?
The PipeWorx 400 wire feeder supports wire diameters from 0.9mm to 1.6mm (0.035 to 0.062 inches). The maximum spool weight is 27 kg (60 lb), and wire feed speed ranges from 1.3 to 19.8 m/min (50 to 780 in/min). (Page 12)
Show 50 more questions
How long should I wait before touching internal components after powering down the PipeWorx 400?
How do I enable the 14-pin remote control receptacle for stick (SMAW) welding?
What is the duty cycle of the PipeWorx 400 in MIG welding mode?
What should I do if the machine overheats during welding?
How do I restore the PipeWorx 400 to factory settings?
What type of coolant should I use with the PipeWorx 400 cooler?
What input voltages are supported by the PipeWorx 400?
How do I change the wire feeder speed display from inches per minute to meters per minute?
What are the duty cycle ratings for the PipeWorx 400 in MIG welding mode?
What is the maximum rated output of the wire feeder?
Where are the diagnostic fault codes for the PipeWorx 400 documented?
What safety precaution must be taken before performing maintenance inside the PipeWorx 400?
What welding processes does the Miller Pipeworx 400 support?
How do I set up and install the Miller Pipeworx 400?
What is the wire feed speed range for the Pipeworx 400?
How do I troubleshoot no arc output on the Pipeworx 400?
What does error code E1 mean and how do I fix it?
What does error code E2 mean on the Miller Pipeworx 400?
How do I fix an erratic arc on the Pipeworx 400?
Can the Pipeworx 400 be used for aluminum welding?
What is the maximum duty cycle of the Miller Pipeworx 400?
Does the Pipeworx 400 have memory storage for welding programs?
What is the rated output and duty cycle for MIG welding on the PipeWorx 400?
What should I do if the unit overheats during MIG welding?
How do I change the wire feed speed display from inches per minute (IPM) to meters per minute (MPM)?
What input voltage options are available for the PipeWorx 400, and how do I select the correct one?
What fuse size is recommended for the PipeWorx 400 when running on 460-volt, three-phase input power?
What coolant must I use in the PipeWorx 400 cooler, and what happens if I use a different coolant?
How do I enable the Remote 14 receptacle control for Stick welding?
What is the wire diameter range and wire feed speed range supported by the PipeWorx 400 wire feeder?
What is the total weight of the complete PipeWorx 400 welding system, and how should it be safely lifted?
What is the minimum clearance required around the PipeWorx 400 for proper ventilation and placement?
What should I check if my PipeWorx 400 is producing an erratic arc?
How many welding programs can the memory feature store?
What is the duty cycle rating of the PipeWorx 400?
What should I do if there is no arc output from my PipeWorx 400?
What input power options are available for the Miller PipeWorx 400?
How do I set up the Miller PipeWorx 400 when first installing it?
What does error code E1 mean on the PipeWorx 400?
Can the Miller PipeWorx 400 weld aluminum?
Why am I not getting any arc output from my welding machine?
Can I use the PipeWorx 400 for welding aluminum?
What is the maximum duty cycle of the PipeWorx 400?
What are the first steps to set up my Miller PipeWorx 400 when I first receive it?
How do I use the memory feature to store my welding settings?
Does the PipeWorx 400 support dual-wire feeding?
What should I do if my arc is unstable or erratic?
How do I select and change welding processes on the PipeWorx 400?
What input power options are available for the PipeWorx 400?
What is the maximum wire feed speed for the Miller PipeWorx 400?
Full Manual
112 pages
Om-236 891G
2010−04 Processes MIG (GMAW) and Pulsed MIG (GMAW-P) Welding Multiprocess Welding Description PipeWorx 400 Welding System (230/460 And 575 Volt Models) File: MIG (GMAW) Visit our website at www.MillerWelds.com TIG (GTAW) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding Arc Welding Power Source Wire Feeder
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Thank 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 2009−09
Table Of Contents
Section 1 − Safety Precautions - Read Before Using
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 2 − Consignes De Sécurité − Lire Avant Utilisation
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symboles utilisés 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . . 2-4. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de sécurité 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Informations relatives aux CEM 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 3 − Installation
11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. MIG Duty Cycle and Overheating 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Stick And TIG Duty Cycle and Overheating 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Serial Number And Rating Label Location 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Selecting a Location 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Remote 14 Accessory Receptacle Information 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Turning On Remote 14 Receptacle Control For Stick 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Changing Wire Feed Speed From Inches Per Minute (IPM) To Meters Per Minute (MPM) 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Remote 14 Wire Feeder Control Receptacle Information 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. Supplementary Protector CB2 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11. 115 Volts AC Single Receptacle And Supplementary Protector 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12. Lifting Eye On Power Source 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13. Electrical Service Guide 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14. Selecting Input Voltage (230/460 Volt Models Only) 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15. Connecting Input Power 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16. Installing Optional Handles, Running Gear And Cooler 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17. Assembling And Installing Cable Hanger 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18. Weld Output Terminals And Selecting Cable Sizes* Recommended For PipeWorx 400 27 . . . . . . . . . . . 3-19. Connecting Weld Output Cables 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20. Proper Ring Terminal Connection To Volt Sense Lead 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21. Connecting Volt Sense Lead And Work Cable To Clamp 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Power Source 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Cart 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24. Wire Feeder Rear Panel Connections And Rotating Drive Assembly 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25. Gun Trigger Receptacle 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26. Installing And Threading Welding Wire 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs 35 . . . . . . . . . . . . . . . . . . 3-28. Arranging Welding Cables To Reduce Welding Circuit Inductance 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29. Typical Connection Diagram For Stick (SMAW) Equipment 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30. Typical Connection Diagram For Two Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31. Typical Connection Diagram For One Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32. Typical Connection Diagram For Liquid-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table Of Contents
Section 4 − Operation
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Operational Terms 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Welding Power Source Controls 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Stick Process Selection Setup Example 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. TIG Process Selection Setup Example 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. MIG Process Selection Setup Example 1 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. MIG Process Selection Setup Example 2 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Wire Feeder Controls 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Postflow Adjustment 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Wire Feeder Left Side Active Setup Example 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Wire Feeder Right Side Active Setup Example (Dual Feeder Only) 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Wire Feeder Non-MIG Setup Example 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Wire Feeder Timed Purge Example 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13. Wire Feeder Auto Jog Example 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14. Basic Parameters For PipeWorx 400 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15. Lift-ArcE And HF TIG Start Procedures 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 5 − Maintenance And Troubleshooting
66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Blowing Out Inside of Unit 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Restoring Factory Defaults 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Viewing Software Revision 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Power Source Calibration Procedure 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460 Volt Models 69 . . . . . . . 5-7. Removing Right Side Panel and Measuring Input Capacitor Voltage In 575 Volt Models 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Cooler Routine Maintenance 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Coolant Maintenance 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. Welding Power Source And Feeder Diagnostic Help Codes 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11. Troubleshooting Welding Power Source/Wire Feeder Issues 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. Welding Power Source Troubleshooting 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13. Wire Feeder Troubleshooting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14. Cooler Troubleshooting 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 6 − Electrical Diagram
80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 7 − Parts List
86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warranty
OM-236 891 Page 1
Section 1 − Safety Precautions - Read Before Using
som _2010−03 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text. NOTICE − Indicates statements not related to personal injury. Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards. 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. Additional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoid- able or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! 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. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present. 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 in inverter weld- ing power sources AFTER removal of inputpower. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equip- ment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-236 891 Page 2 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 local forced ventilation at the arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDSs) and the 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. 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. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks 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, glare and sparks; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection. ARC RAYS can burn eyes and skin. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. 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. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding 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). Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, 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. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or by- pass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL or DIRT 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.
Electric And Magnetic Fields (Emf)
can affect ImplantedMedical Devices. Wearers of Pacemakers and other Implanted Medical Devices should keep away. Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. 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, physical damage, 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. Use the right equipment, correct procedures, and sufficient num- ber of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
OM-236 891 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 EQUIPMENT can injure. 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. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manu- ally lifting heavy parts or equipment. OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. FLYING SPARKS can injure. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires — keep flammables away. 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 injure. Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. MOVING PARTS can injure. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
Read Instructions.
Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. 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.
OM-236 891 Page 4 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. This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproduc- tive 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. 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob- al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov). Applications Manual for the Revised NIOSH Lifting Equation, The Na- tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 1-6. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may inter- fere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, access restrictions for passers−by or individual risk assess- ment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
OM-236 891 Page 5
Section 2 − Consignes De Sécurité − Lire Avant Utilisation
fre_som_2010−03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dan- gers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. NOTE − Indique des déclarations pas en relation avec des blessures personnelles. Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger. 2-2. Dangers relatifs au soudage à l’arc Les symboles représentés ci-dessous sont utilisés dans ce ma- nuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Sec- tion 2-5. Lire et observer toutes les normes de sécurité. Seul un personnel qualifié est autorisé à installer, faire fonc- tionner, entretenir et réparer cet appareil. Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil. UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits inter- nes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalli- ques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. Ne pas toucher aux pièces électriques sous tension. Porter des gants isolants et des vêtements de protection secs et sans trous. S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol. Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique à courant électrique UNIQUE- MENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. D’autres consignes de sécurité sont nécessaires dans les condi- tions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est re- commandée. En outre, ne pas travailler seul ! Couper l’alimentation ou arrêter le moteur avant de procéder à l’in- stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor- mes de sécurité). Installer le poste correctement et le mettre à la terre convenable- ment selon les consignes du manuel de l’opérateur et les normes nationales, provinciales et locales. Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. En effectuant les raccordements d’entrée, fixer d’abord le conduc- teur de mise à la terre approprié et contre-vérifier les connexions. Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes. Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort. L’équipement doit être hors tension lorsqu’il n’est pas utilisé. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi- sante ou mal épissés. Ne pas 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 provenant d’une autre machine. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide dou- blée. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le- champ les pièces endommagées. Entretenir l’appareil conformé- ment à ce manuel. Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. S’assurer que tous les panneaux et couvercles sont correctement en place. Fixer le câble de retour de façon à obtenir un bon contact métal- métal avec la pièce à souder ou la table de travail, le plus près pos- sible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage.
OM-236 891 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. Eloigner votre tête des fumées. Ne pas respirer les fumées. À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégrais- seurs. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et for- mer des gaz hautement toxiques et irritants. Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revête- ment n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intense (ultraviolets et infrarouges) susceptibles de provoquer des brûlure dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. Porter des vêtements confectionnés avec des matières résistan- tes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les nor- mes de sécurité). Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va- peurs inflammables (vapeur d’essence, par exemple). Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provo- quant des risques d’électrocution, d’étincelles et d’incendie. 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 à la pointe de contact. Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. Avant de souder, retirer toute substance combustible de vos po- ches telles qu’un allumeur au butane ou des allumettes. Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-236 891 Page 7
Les
Accumulations
De
Gaz
risquent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non-utilisation. Veiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction. LE BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- magée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. LES BOUTEILLES peuvent exploser si elles sont endommagées. Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Placer les bouteilles debout en les fixant dans un support station- naire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état. Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille. Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur. Utiliser les équipements corrects, les bonnes procédures et suffi- samment de personnes pour soulever et déplacer les bouteilles. Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécu- rité. 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OUD’Explosion.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Ne pas installer l’appareil à proximité de pro- duits inflammables. Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.L’Emploi
Excessif
peutSurchauffer L’Équipement.
Prévoir une période de refroidissement ; res- pecter le cycle opératoire nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages d’air du poste.Les Étincelles Projetées
peuvent provoquer des blessures. Porter un écran facial pour protéger le visage et les yeux. Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps. Les étincelles risquent de causer un incendie − éloigner toute sub- stance inflammable.Les Charges Électrostati-
QUES peuvent endommager les cir- cuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antista- tiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
OM-236 891 Page 8 Les PIÈCES MOBILES peuvent causer des blessures. Ne pas s’approcher des organes mobiles. Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. Les PIÈCES MOBILES peuvent causer des blessures. S’abstenir de toucher des organes mobiles tels que des ventilateurs. Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qua- lifié. Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.
Lire Les Instructions.
Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’instal- lation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.Le
Rayonnement
Haute
Fréquence
(H.F.)
risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité et les ordi- nateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installa- tion. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’ap- pareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- ce correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. LE SOUDAGE À L’ARC risque de provoquer des interférences. L’énergie électromagnétique risque de provoquer des interférences pour 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 compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipe- ment électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précéden- tes, il incombe à l’utilisateur de prendre des mesures supplé- mentaires telles que le déplacement du poste, l’utilisation de câ- bles blindés, l’utilisation de filtres de ligne ou la pose de protec- teurs dans la zone de travail. 2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimi- ques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipu- lation. Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation. Pour les moteurs à essence : Les gaz d’échappement des moteurs contiennent des pro- duits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Pour les moteurs diesel : Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie com- me provoquant des cancers et des malformations congénitales ou autres problèmes de procréation.
OM-236 891 Page 9 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com). National Electrical Code, NFPA Standard 70, de National Fire Protec- tion Association, Quincy, MA 02269 (téléphone : 800-344-3555, site Internet : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan- tilly, VA 20151 (téléphone : 703-788-2700, site Internet : www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone : 800-463-6727, site internet : www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, site Internet : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet : www.osha.gov). U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site inter- net : www.cpsc.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet: www.cdc.gov/NIOSH). 2-6. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Les CEM peuvent créer des interférences avec certains implants médicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:
OM-236 891 Page 10
OM-236 891 Page 11
Section 3 − Installation
3-1. SpecificationsA.
Welding Power Source Specifications Input Power Weld- ing Pro- cess Rated Weld- ing Output Amperage Range Setting (CC Pro- cess) Voltage Range Setting (CV Pro- cess) Maxi- mum Open- Circuit VoltageDc
Amperes Input At Rated Load Output 60 Hz, Three-PhaseKva
Kw
230 V
460 V
575 V
230 460 575 230 460 575 Three Phase Stick350 A @ 34
Volts DC, 100% Duty Cycle 40 − 350 — — 90 36.8 22.5 18.9 14.8 18.0 19.0 13.7 13.7 13.8Tig
350 A @ 34
Volts DC, 100% Duty Cycle 10-350 — — 36.8 22.5 18.9 14.8 18.0 19.0 13.7 13.7 13.8Mig
400 A @ 44
Volts DC, 100% Duty Cycle — — 10-44 53.6 31.1 26.0 21.5 24.7 25.9 20.0 19.9 19.7 Flux Cored400 A @ 44
Volts DC, 100% Duty Cycle — — 10-44 53.6 31.1 26.0 21.5 24.7 25.9 20.0 19.9 19.7 To appropriately size circuit protection see Section 3-13.B.
Dimensions And Weight Hole Layout DimensionsA
B
C
D
E
805 142-A
31-3/4 in. (806 mm) 19-1/2 in. (495 mm) 28-1/2 in. (724 mm)A
19-1/2 in. (495 mm)B
16-7/8 in. (424 mm)C
31-3/4 in. (806 mm)D
16 in. (406.4 mm)E
5/16-18 in. UNC thread Weight 225 lb (102 kg)
OM-236 891 Page 12
C.
Wire Feeder Specifications Input Power Welding Power Source Type Wire Feed Speed Range Wire Diameter Range Welding Circuit RatingIp
Rating Overall Dimensions Weight Single Dual 24 Volts AC 11 Amperes PipeWorx 400 50 To 780 ipm (1.3 To 19.8 mpm) .035 To .062 in (0.9 To 1.6 mm) Max Spool Weight: 60 lb (27 kg) 100 Volts, 750 Amperes, 100% Duty CycleIp 21
Length: 29 in. (737 mm) Width: 19 in. (483 mm) Height: 14 in. (356 mm) 65 lb (30 kg) 90 lb (41 kg)D.
Cooler Specifications Input Power Overall Dimensions Coolant Capacity Weight Pump Blower Net Wet Weight 115 Volts AC 115 Volts AC Length: 29 in. (737 mm) Width: 19-3/8 in. (492 mm) Height: 12 in. (305 mm) 3 gal (11.4 L) 108 lb (49 kg) 133 lb (60 kg)E.
Coolant Chart Low Conductivity Coolant No. 043 810* *Coolant 043 810 protects to -37° F (-38° C) and resist algae growth. Coolant NOTICE − Use of any coolant other than that listed in the table voids the warranty on any parts that come in contact with the coolant (pump, radiator, etc.).
OM-236 891 Page 13 3-2. MIG Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit and void warranty. Overheating 0 15
A/V
Or
Reduce Duty Cycle Minutes duty1 4/95 − 240 110-A Continuous Welding 100% Duty Cycle At 400 Amperes 60% Duty Cycle At 565 Amperes 6 Minutes Welding 4 Minutes Resting 3-3. Stick And TIG Duty Cycle and Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage, voltage, wire feed speed, or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit and void warranty. Overheating 0 15A/V
Or
Reduce Duty Cycle Minutes duty1 4/95 − 240 110-A Continuous Welding 100% Duty Cycle At 350 Amperes
OM-236 891 Page 14 3-4. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 3-5. Selecting a Location loc_2 3/96 − Ref. 805 142-A 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Line Disconnect Device Locate unit near correct input power supply. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Movement Location 18 in. (460 mm) 18 in. (460 mm) 3 Tipping ! Do not move or operate unit where it could tip.
Or
1 2
OM-236 891 Page 15 3-6. Remote 14 Accessory Receptacle Information If a remote control is connected to the Remote 14 receptacle, the unit will automatically adjust output control to a primary/secondary configuration. In this configuration, the Amperage Adjust knob on the unit becomes the primary and sets the maximum amperage output of the unit. The remote control becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage Adjust knob setting. The Remote 14 receptacle is factory set to be active in TIG mode only. As an option, this receptacle may also be enabled in Stick mode (see Section 3-7).
A
J
B
K
I
C
L
N
H
D
M
G
E
F
805 143--A
Socket* Socket Information15 Volts Dc
A
15 volts DC.B
Contact closure to A completes 15 volts DC contactor control circuit.Remote
Control
C
Output to remote control; +10 volts DC.D
Remote control circuit common.E
0 to +10 volts DC input command signal from remote control.Gnd
K
Chassis common. *The remaining sockets are not used.
OM-236 891 Page 16 3-7. Turning On Remote 14 Receptacle Control For Stick
805 288-A
! Turn Off welding power source, disconnect input power, and check voltage on input capacitors accord- ing to Section 5-6 before proceeding. When this control is active and a current/contactor control is connected to the Remote 14 receptacle on the power source front panel, the contactor and primary/secondary amperage control will function in both TIG and Stick modes. 1 User Interface Board 2 Dip Switch Remove feeder and side mount cable hangers from top of unit, if applicable. Remove top cover from power source. Move number 2 switch to the up position (on stick side). Use a small screwdriver to move switch, if necessary. Reinstall cover. Replace side mount cable hangers and feeder to top of unit, if applicable. 2 Tools Needed: 1 5/16 in. Stick Remote Off Stick Remote OnOn
On
1 1 2 2
OM-236 891 Page 17 3-8. Changing Wire Feed Speed From Inches Per Minute (IPM) To Meters Per Minute (MPM)
805 298-A / 805 429-A
! Turn Off welding power source, disconnect input power, and check voltage on input capacitors accord- ing to Section 5-6 before proceeding. 1 PipeWorx Feeder 2 Operator Interface Board 3 Dip Switch Remove feeder wrapper. Move number 1 switch (top switch) to the ON position. Use a small screwdriver to move switch, if necessary. Reinstall wrapper. Tools Needed: 5/16 in. 1 2 3 Rear View Of Wire Feeder Front Panel
OM-236 891 Page 18 3-9. Remote 14 Wire Feeder Control Receptacle Information Ref. 805 144-A / Ref. 048 286-B
Ì
Ì
Remote 14 Feeder Control Socket* Socket Information24 Volts Ac
8, 12 24 volts AC. Protected by supplementary protector CB2. 1,4 24 volts AC return. Connected to chassis common. Completes 24 volts AC power supply circuit to feeder.Serial
Communication
6 Isolated RS-485 (+) serial communication signal. 3 Isolated RS-485 (−) serial communication signal. 5 Isolated serial communication common.Positive Volt Sense
14 Positive weld output voltage sense signal.Negative Volt Sense
11 Negative weld output voltage sense signal.Gnd
2,10 Chassis common. *The remaining sockets are not used.
OM-236 891 Page 19 3-10. Supplementary Protector CB2
805 298-A
1 Supplementary Protector CB2 CB2 protects the 24 volts ac power supply to the wire feeder (see Section 3-9). Press button to reset supplementary protector. 1MigOutput
TigGasIn
Cb2
ToWireFeeder
OM-236 891 Page 20 3-11. 115 Volts AC Single Receptacle And Supplementary Protector
805 143-A
1 115 V 10 A AC Receptacle (Cooler Power Supply Only When Power Source Is On) 2 Supplementary Protector CB1 CB1 protects single 115 volt AC receptacle. Press button to reset supplementary protector. 2 1Use 2/0 Cable Minimum
OM-236 891 Page 21 3-12. Lifting Eye On Power Source
805 293-A
! Turn Off welding power source, disconnect input power. 1 Lifting Eye The wire feeder allows access to the lifting eye on the power source. The entire welding system as shown with cable hangers, cooler with coolant, dual feeder, and running gear can be lifted with the lifting eye. The control cable must be disconnected from the feeder. Use of a lifting strap may be necessary. Total weight is approximately 525 lb (238 kg) excluding welding guns and cables. Be sure that wire spools, cables and gas bottles are removed before lifting the welding system. 1
OM-236 891 Page 22 3-13. Electrical Service Guide NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency10%) and voltage 10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera- tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source. NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Three Phase Input Voltage (V) 230 460 575 Input Amperes (A) At Rated Output 61 34 29 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay Fuses 2 80 40 30 Normal Operating Fuses 3 100 50 40 Min Input Conductor Size In AWG 4 6 8 10 Max Recommended Input Conductor Length In Feet (Meters) 148 (45) 386 (118) 402 (122) Min Grounding Conductor Size In AWG 4 8 10 10 Reference: 2008 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-236 891 Page 23 3-14. Selecting Input Voltage (230/460 Volt Models Only) Ref. 805 142-A / 805 145-B ! Turn Off welding power source, disconnect input power, and check voltage on input capacitors accord- ing to Section 5-6 before proceeding. Check input voltage available at site. 1 Voltage Selection View Window Check voltage selected in unit. Changing selection is only necessary if selected value does not match available input voltage. 2 Relinking Board PC10 In 230 VAC Position 3 Mounting Screws 4 Receptacle RC8 (Connection For 230 VAC Input Power) 5 Receptacle RC7 (Connection For 460 VAC Input Power) 6 Relinking Board PC10 In 460 VAC Position Move relinking board as needed and connect plug PLG4 (in unit) to RC8 or RC7 according to input power voltage. Tools Needed: 5/16 in. Be sure to reinstall all four screws se- curing relinking board in place. 1 6 2 3 3 4 5
OM-236 891 Page 24 3-15. Connecting Input Power
805 146-A
! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tag- out input power before con- necting input conductors from unit. ! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. Right side panel can be removed to allow attaching primary cable even with handles installed. 1 Input Power Cord. 2 Disconnect Device (switch shown in the OFF position) 3 Green Or Green/Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors (L1, L2 AndL3)
6 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1, L2, and L3 to disconnect device line terminals. 7 Over-Current Protection Select type and size of over-current protection using Section 3-13 (fused disconnect switch shown). 8 Strain Relief Connector Clamp Obtain and install proper connector. 9 Contactor W1 Select size and length using Section 3-13. Connect as shown in illustration. Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. Tools Needed: 5/16 in.L1 L2 L3
1 8 9L1
2 1L2
L3
3 3 4 5 6 7 =Gnd/Pe
Earth Ground
OM-236 891 Page 25 3-16. Installing Optional Handles, Running Gear And Cooler
805 302-A / 805 292-A
! Turn Off welding power source, disconnect input power. 1 Running Gear 234 359 2 Cooler 3 Wheel 163 463 (2) 4 Flat Washer 602 250 (4) 5 Retaining Ring 121 614 (2) Install wheels on cylinder tray as shown. Set cooler on running gear. If not installing a cooler, set power source on running gear. 6 Flat Washer 602 240 (4) 7 Lock Washer 602 211 (4) 8 Screw 601 944 (4) Secure cooler to running gear using supplied flat washers, lock washers and screws. 9 Power Source Set power source on cooler. Secure power source to cooler using same hardware that was used to secure cooler to running gear. 10 Cylinder Support Bracket 11 Bushing 170 647 (2) 12 Bushing 004 214 (1) 13 Screw 128 237 (4) 14 Chain 188 441 (2) Install cylinder support bracket to rear of power source and secure with supplied screws. Install bushings and chains. 15 Handle Bracket 16 Handle (2) 17 Tube Cap (4) Install tube caps into ends of handles. Remove 5 screws above louvered panel on front of power source. Attach handle bracket to front of power source using the 5 screws previously removed. Remove 2 screws on the side of the cover on front of power source. 18 Screw 234 483 (2) Start supplied upper handle mounting screws into handles by hand on each side of power source. 19 Screw 604 535 (2) 20 Lock Washer 602 211 (2) 21 Flat Washer 602 240 (2) Start supplied screws, lock washers and flat washers into handle bracket by hand on each side of power source. 22 Screw 604 535 (4) 23 Lock Washer 602 211 (4) 24 Flat Washer 602 240 (4) Start supplied lower handle mounting screws, lock washers and flat washers into handles by hand on each side of power source. Tighten all handle hardware. Tools Needed: 1/2 in. 5/16 in. 2 6 7 8 9 1 2 3 4 15 16 5 6 7 8 13 18 19 2021 22 23 24 17 10 9 11 12 11 14
OM-236 891 Page 26 3-17. Assembling And Installing Cable Hanger
805 148-B / 805 141-A
1 Bracket 2 Tube Cap (4) 3 Cable Holder Tube (2) Install caps in tubes. Assemble cable holder tubes to bracket using supplied hardware. Place cable holder assembly on top of power source or cart and set wire feeder on cable hanger. Tools Needed: 7/16 in. 3/8 in. 1 2 3
OM-236 891 Page 27 3-18. Weld Output Terminals And Selecting Cable Sizes* Recommended For PipeWorx 400 NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size. ! Turn off power before connecting to weld out- put terminals. ! Do not use worn, dam- aged, undersized, or poorly spliced cables. Weld Output Terminals Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Welding Amperes 10 − 100% Duty Cycle Stick (+)
805 143-A
Tig (−)
Work 100 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70 150 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 3/0 (95) 3/0 (95) 200 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 250 2/0 (70) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 300 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 350 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 400 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120) 500 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 3/0 (3x95) 600 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120)
OM-236 891 Page 28 3-19. Connecting Weld Output Cables
803 778-B
! Turn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean. Tools Needed: 3/4 in. (19 mm) 4 2 3 Do not place anything between Incorrect Installation 1 weld cable terminal and copper bar.
OM-236 891 Page 29 3-20. Proper Ring Terminal Connection To Volt Sense Lead If volt sense lead is cut or broken at end with ring terminal, be sure that new ring ter- minal is connected as shown. 1 Jacket 2 Insulated Tape Or Heat-Shrink Tubing 3 Center Conductor 10 ga 4 Ring Terminal 1/2 in. Opening 1 Tools Needed: 3 4 2 Ref. 239 780-B 3-21. Connecting Volt Sense Lead And Work Cable To Clamp
805 030-A
Tools Needed: 1/2 in. 3 2 1 1 Volt Sense Lead 2 Work Cable 3 Clamp Be sure that volt sense lead ring terminal is on top of work cable ring terminal when connecting to clamp. Connect volt sense lead and work cable to clamp. 1/2 in.
OM-236 891 Page 30 3-22. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Power Source ! Do not put feeder where welding wire hits cylinder. ! Do not move or operate equipment when it could tip. 1 Welding Power Source 2 Wire Feeder 3 MIG Connection 4 Positive (+) Weld Cable 5 Feeder Control Cable Connection 6 Gas Hose 7 Gas Cylinder Connect 14-pin plug to rear of power source, and connect 14-socket plug to rear of wire feeder. Connect one end of weld cable to weld terminal on rear of power source. Connect remaining end of weld cable to wire feeder drive housing. Connect one end of gas hose to regulator/flowmeter on gas cylinder and connect remaining end of gas hose to gas solenoid connector on rear of feeder or Y-hose for dual wire feeder. 8 Work (−) Weld Cable Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. 9 Volt Sense Cable 10 Workpiece 11 Welding Gun
805 144-B
8 11 9 10 1 6 4 7 2 5 3 9
OM-236 891 Page 31 3-23. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Cart ! Do not put feeder where welding wire hits cylinder. ! Do not move or operate equipment when it could tip. 1 Welding Power Source 2 Wire Feeder 3 Feeder Cart 4 Composite Cable 5 MIG Connection 6 Positive (+) Weld Cable 7 Gas Hose 8 Gas Cylinder Locate end of composite cable where gas hose extends out of sleeve approximately 50 inches (1270 mm). This end of the composite cable connects to the power source. Connect 14-pin plug to rear of power source, and connect 14-socket plug to rear of wire feeder. Connect one end of weld cable to weld terminal on rear of power source and secure cable in clamp block on rear panel. Connect remaining end of weld cable to wire feeder drive housing and secure cable in clamp block on feeder base. Connect one end of gas hose to regulator/flowmeter on gas cylinder and connect remaining end of gas hose to gas solenoid connector on rear of feeder or Y-hose for dual wire feeder. 9 Work (−) Weld Cable (2/0 minimum) Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. 10 Volt Sense Cable 11 Workpiece 12 Welding Gun 13 Strain Relief Clamp
805 317-B
6 10 7 1 4 2 5 8 3 10 11 9 12 13 13
OM-236 891 Page 32 3-24. Wire Feeder Rear Panel Connections And Rotating Drive Assembly 805 155-A / Ref. 804 766-A / 802 825-A 1 14-Pin Control Cable 2 Shielding Gas Valve Fittings Requires fitting with 5/8-18 right-hand threads. Connect customer-supplied gas hose. 3 Weld Cable Terminal 4 Jumper Weld Cable From Right Side Drive Assembly (Dual Model Only) 5 Weld Cable 6 Drive Assembly 7 Drive Assembly Rotation Knob To rotate the drive assembly, loosen drive assembly rotation knob, rotate drive assembly, and tighten knob. 8 Rating Label Location 9 Volt Sense Terminal 9/16, 5/8 in. Tools Needed: 3/16 in. 6 7 3 9 4 5 2 1 8 2 9
OM-236 891 Page 33 3-25. Gun Trigger Receptacle
805 154-A
1 Left Gun Trigger ReceptacleRc2
2 Right Gun Trigger Receptacle RC3 (Dual Model Only) Connect gun trigger plug to appropriate receptacle on feeder. 1 2
OM-236 891 Page 34 For best wire feeding performance, be sure that the outlet cable has the prop- er size liner for the welding wire size be- ing used. Also, when the gun is installed, the liner extending from the back of the gun should be as close to the drive rolls as possible, without touching. Install gun. Lay gun cable out straight. Cut off end of wire. Push wire through guides up to drive rolls; continue to hold wire. Press Jog button to feed wire out gun. For soft wire or small diameter stain- less steel wire, reduce drive roll pressure on the rear roll to half that of the front rolls. To adjust drive roll pressure, hold nozzle about 2 in (51 mm) from nonconductive surface and press gun trigger to feed wire against surface. Tighten knob so wire does not slip. Do not overtighten. If contact tip is completely blocked, wire should slip at the feeder (see pressure adjustment above).Cut wire off. Close cover. 3-26. Installing And Threading Welding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 804 743-A Tools Needed:
Nonconductive
Surface
Nonconductive
Surface
No Wire Slip Wire Slips Install wire spools. Adjust tension nuts so wire is taut when wire feed stops. Install wire guides and anti-wear guide. Install drive rolls. 3/16, 5/64 in. 15/16, 3/8 in. Pressure Adjust Front Rolls Pressure Adjust Rear Rolls Drive Rolls End Of Liner Back Of Gun Pressure Indicator Scale
OM-236 891 Page 35 3-27. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs
A.
Ideal Setup805 289-B
1 Welding Power Source 2 Composite Cable 3 Work Cable 4 Volt Sense Lead The volt sense lead must be used to provide an accurate voltage feedback signal to the welding system. Use of this lead is critical for stable welding performance. 5 Wire Feeder 6 Workpiece This arrangement is an ideal setup for supporting separate voltage feedback to the welding power sources. The most accurate voltage sensing may not be achieved due to voltage drops in the workpiece. This may require compensation in the welding parameters. 1 2 3 4 5 6 1 2 3 4 5
OM-236 891 Page 36
B.
Bad Setup805 290-B
1 Welding Power Source 2 Composite Cable 3 Work Cable 4 Voltage Sensing Lead 5 Wire Feeder 6 Workpiece This arrangement is a bad setup due to sensing leads being directly in the current flow path of the welding arc. Interaction between welding circuits will affect voltage drop in the workpiece. The voltage drop across the workpiece will not be measured correctly for the voltage feedback signal. Voltage feedback to the welding power sources will not be correct at either sense lead and result in poor arc starts and arc quality. 1 2 3 4 5 6
OM-236 891 Page 37
805 291-B
1 Welding Power Source 2 Composite Cable 3 Work Cable 4 Volt Sense Lead 5 Wire Feeder 6 Workpiece The method used to arrange cables has a significant affect on welding performance. As an example, Pro-Pulse and RMD welding processes can produce high welding circuit inductance depending on cable length and arrangement. This can result in limited current rise during droplet transfer into the welding puddle. The electrode sense and volt sense leads are contained in the feeder control cable and are enabled for all processes. The volt sense lead automatically compensates for work cable voltage drop when connected to the welding power source. Do not coil excess cables. Use cables that are the appropriate length for the application. Avoid coupling the volt sense lead with the weld cables. 3-28. Arranging Welding Cables To Reduce Welding Circuit Inductance Bad DO NOT coil cables DO NOT share work clamps (no more than 1 machine per clamp) DO NOT tangle cables from different machines DO NOT splice weld cables Ideal Use shortest cables possible for the job Use proper sized work clamp and weld cables to accommodate peak amperages Separate volt sense lead and feeder control cable from weld cables Place weld cables together if possible Connect work clamp as close to welding arc as possible 1 2 3 4 5 6 1 5 4 2 3 6
OM-236 891 Page 38
805 294-A
1 Welding Power Source 2 Work (−) Weld Cable 3 Stick (+) Weld Cable 4 Workpiece 5 Electrode Holder 6 Volt Sense Lead Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. 3-29. Typical Connection Diagram For Stick (SMAW) Equipment 1 2 3 5 4 6
OM-236 891 Page 39
805 295-A
1 Welding Power Source 2 Gas Hose 3 TIG (−) Weld Cable 4 Work (+) Weld Cable 5 Workpiece 6 TIG Torch 7 Volt Sense Lead 8 Remote Foot Control (Optional) Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. 3-30. Typical Connection Diagram For Two Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 1 2 3 4 6 5 7 8
OM-236 891 Page 40
805 296-A
1 Welding Power Source 2 Gas Hose 237 415 (Short Black Hose Supplied With Power Source) 3 TIG Block (Customer Supplied) 4 TIG (−) Weld Cable 5 Work (+) Weld Cable 6 Workpiece 7 TIG Torch 8 Volt Sense Lead 9 Remote Foot Control (Optional) Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. 3-31. Typical Connection Diagram For One Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 1 2 3 4 5 6 7 8 9
OM-236 891 Page 41
805 297-A
1 Welding Power Source 2 Gas Hose 3 TIG Block (Customer Supplied) 4 Coolant Out Hose 237 416 (Short Red Hose Supplied With Cooler) 5 TIG (−) Weld Cable 6 Coolant Return Hose 7 Work (+) Weld Cable 8 Workpiece 9 TIG Torch 10 Volt Sense Lead 11 Remote Foot Control (Optional) Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. 3-32. Typical Connection Diagram For Liquid-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 1 2 6 4 5 3 7 8 9 10 11
OM-236 891 Page 42
Section 4 − Operation
4-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: 98/2 Ox Gas mixture of 98% Argon and 2% O2. Amps Indicates average amperage while welding and holds the value for 10 seconds at end of weld. Arc Control The adjustment of arc cone width and arc characteristics in the RMD and Pulse processes. Increasing Arc Control value increases the arc cone width and subsequently effects the arc length (end of electrode to workpiece). See Section 4-7 items 1 and 4 for adjusting Arc Control value. Arc Length Distance from end of wire electrode to workpiece. This term is also used to represent arc length adjustments in RMD and Pulse processes. Increasing Arc Length increases the actual arc length; likewise, decreasing Arc Length shortens actual arc length. See Section 4-7 items 2 and 3 for adjusting arc length value. Base Material Selection of material to be welded (Carbon or Stainless Steel).C2
Gas mixture of 98% Argon and 2% CO2.C20-C25
Gas mixture of mainly Argon and 20-25% CO2.C8-C15
Gas mixture of mainly Argon and 8-15% CO2. Dual Schedule A two position switch which attaches to (or incorporated in) the gun handle that can be used to change weld parameters during the MIG welding processes. The gun trigger operates as a standard trigger. Dual Schedule is always activated. See Section 4-2 item F 8 for setup procedure.Exx10
Stick welding electrode type. EXXX1 or EXXX2 are typically used on this setting (cellulosic electrode).Exx18
Stick welding electrode type. EXXX3 through EXXX8, or stainless are typically used on this setting (low hydrogen type electrode). FCAW (Flux Cored Arc Welding) Flux cored arc welding is a continuous electrode that is fed into the arc and depends on shielding gas from either an external source or is generated from the decomposition of gas forming ingredients contained in the electrode’s core. Only dual shielded wire is recommended for the PipeWorx 400. A gas mixture or wire diameter selection is not required. See wire manufacturer for the recommended gas mixture. The 0.035 to 0.062 wire sizes can be used in the process. Gas Type Selection of shielding gas being used in an application: C8-C15 (Argon/8-15% CO2), C20-C25 (Argon/20-25% CO2), C2 (Argon/2% CO2), 98/2 Ox (Argon/2% O2), TRI H (90% Helium/7.5% Argon/2.5% CO2), TRI A (81% Argon/18% Helium/1% CO2).Hf
TIG starting method. High frequency turns on to help start the arc when output is enabled. High frequency turns off when arc is started and turns on whenever the arc is broken to help restart the arc. HF start is used for GTAW process when a non-contact arc start method is required. Inductance Control Allows setting inductance in MIG and FCAW. In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes the welding puddle more fluid. See Section 4-7 items 1 and 4 for adjusting Inductance Control value. Jog Method for feeding wire without contactor or gas valve being energized (see Section 4-7, item 9). Lift-Arc TIG starting method. Touch tungsten electrode to workpiece at weld start point and enable output and shielding gas with torch trigger, foot control, or hand control (if a control is desired). Hold electrode to workpiece for one to two seconds, and slowly lift electrode to form the arc. Lift-Arc is used for the GTAW process when HF Start method is not permitted.Mig (Gmaw)
Also referred to as solid wire welding. An arc welding process which joins metals by heating them with an arc. The arc is between a continuously fed filler metal (consumable) electrode and the workpiece. Externally supplied gas or gas mixtures provide shielding. Postflow The time that the shielding gas continues to flow after the arc has been terminated. Process A selection made for MIG, Pulse, RMD, Stick, Flux Core (FCAW), or TIG (Lift-Arc or HF starts). Memory Location Buttons 1-4 By selecting a process such as STICK, TIG, MIG LEFT side of feeder, or MIG right side of feeder there will be four Memory Locations available for selection providing a total of 16 Memory Locations for a dual feeder. There will only be 12 Memory Locations available for a single feeder. Pulse (Pro-Pulse) An advanced pulse spray transfer process suited for the fill and cap passes on pipe. The Pulse process utilizes constant current ramps with constant voltage control of peaks and backgrounds. Adaptive response is controlled by peak and minimum current levels. Benefits are shorter arc lengths, better puddle control, more tolerance of tip-to-work variation, less audible noise, no arc wandering, allows weld to fill in at toes increasing travel speed and deposition, and more tolerant to poor fit up and gaps. Settings for Pulse include Arc Length, Wire Speed and Arc Control. Purge Method for erergizing the gas valve(s) to purge gas lines before welding and to preset gas pressure at the regulator (see Section 4-7, 11).
OM-236 891 Page 43 4-1 . Operational Terms (Continued)
Rmd
RMD stands for Regulated Metal Deposition, a precisely controlled short-circuit transfer process. Benefits of RMD are well suited to root pass welding on pipe, improves gap filling and spatter reduction. Provides less heat input into the workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge materials. Settings for RMD include Arc Length, Wire Speed and Arc Control. Stick (SMAW) Stick (SMAW) welding uses a flux covered consumable electrode that produces a shielding gas and slag to shield the arc and molten weld puddle. Synergic Synergic refers to the unit’s ability to use preprogrammed parameters to determine the actual pulse settings of Peak Amperage, Background Amperage, Pulse Frequency, and Pulse Width at any specific wire feed speed setting. This is a characteristic used in RMD and Pulse processes.Tig (Gtaw)
TIG (GTAW) welding uses a non-consumable tungsten electrode and shielding gas to produce a strong, clean, high quality weld.Tri A
Gas mixture of 81% Argon, 18% Helium and 1% CO2. Trigger Hold This feature reduces weldor fatigue by allowing continuous welding without holding the trigger. See Section 4-7 item 10 to set up the Trigger Hold feature. Trigger Select This feature allows the operator to select MIG processes in Memory Locations 1-4 by pressing the gun trigger. See Section 4-2 item F 6 to set up the Trigger Select feature.Tri H
Gas mixture of 90% Helium, 7.5% Argon and 2.5% CO2. Trim See Arc Length description. Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 10 seconds hold value at end of weld. Wire Diameter Selection of wire diameter for MIG RMD and Pulse processes. The 0.035 or 0.045 wire size must be selected for MIG RMD and Pulse processes. The 0.035 to 0.062 wire sizes can be used with FCAW, but a wire selection is not required.Wfs
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In Pulse and RMD, adjusting wire feed speed also increases power level on wire electrode (one knob control).
OM-236 891 Page 44 4-2. Welding Power Source Controls
A.
Front Panel Controls Only illuminated controls can be changed or adjusted. 1 Memory Card Slot 2 Memory Card Busy Indicator 3 Memory Card Save Button 4 Memory Card Load Button 5 Memory Card Indicator 6 Memory Location Buttons 1-4 7 Stick Process Select Button 8 Stick Electrode Type Select Button 9 Ammeter Display 10 Amperage Adjust Knob 11 TIG Process Select Button 12 TIG Starting Method Select Button 13 MIG Process Type Select Button 14 Base Material Select Button 15 Wire Diameter Select Button 16 Gas Type Select Button 17 Gas Selection Table 18 Trigger Select Button 19 Side Select Button 17 19 18 16 15 14 13 12 11 10 9 8 7 6 5 4 3 1 2 The memory card slot uses an SD memory card. SD Logo is a trademark of the 3C.
OM-236 891 Page 45
B.
Memory Function ControlsC.
Using Optional Memory Card
OM-236 891 Page 46
D.
Memory LocationsE.
Stick And TIG Welding Process Controls
OM-236 891 Page 47
F.
MIG Welding Process Controls The reference to left side feeder controls or left side gun trigger applies to either a single feeder or dual feeder. The reference to right side feeder controls or right side gun trigger only applies to a dual feeder. The controls in the MIG setup panel are only active when in the MIG process. Press and release the SIDE SELECT button to activate the MIG process and the desired feeder side. The LEFT or RIGHT text will illuminate to indicate the the active feeder side (only LEFT will illuminate when using a single feeder). The MIG welding process controls can also be activated at the feeder front panel by pressing LEFT or RIGHT, or by pressing the left or right side gun trigger (see Section 4-7A). The MIG setup panel controls on the welding power source should be selected in order from left to right starting with MIG type and ending with trigger select.
OM-236 891 Page 48
OM-236 891 Page 49 4-3. Stick Process Selection Setup Example Only illuminated controls can be changed or adjusted. 1 Stick Process Active 2 EXX10 Electrode Type Selected 3 Amperage Setting 350A 4 Memory Location 1 Active 1 2 3 4
OM-236 891 Page 50 4-4. TIG Process Selection Setup Example Only illuminated controls can be changed or adjusted. 1 TIG Process Active 2 HF Start Method Selected 3 Amperage Setting 350A 4 Memory Location 2 Active 1 2 3 4
OM-236 891 Page 51 4-5. MIG Process Selection Setup Example 1 Only illuminated controls can be changed or adjusted. 1 MIG Process Active 2 Carbon Steel Base Material Selected 3 0.035 Wire Diameter Selected 4 C8-C15 Gas Type Selected 5 Trigger Select On 6 Side Select Left 7 Memory Location 3 Active 1 2 7 3 4 5 6
OM-236 891 Page 52 4-6. MIG Process Selection Setup Example 2 Only illuminated controls can be changed or adjusted. 1 Pro-Pulse MIG Process Active 2 Stainless Steel Base Material Selected 3 0.035 Wire Diameter Selected 4 TRI-H Gas Type Selected 5 Trigger Select On 6 Side Select Left 7 Memory Location 4 Active 1 2 7 3 4 5 6
OM-236 891 Page 53 4-7. Wire Feeder Controls
A.
Front Panel Controls Only illuminated controls can be changed or adjusted. 1 Left Side Controls Select Button 2 Volts/Arc Length Display 3 Volts/Arc Length Adjust Knob 4 Right Side Controls Select Button* 5 Wire Feed Speed Display 6 Wire Feed Speed Adjust Knob 7 Memory Card Indicator 8 MIG Process Type Indicator 9 Jog Button 10 Trigger Hold Select Button 11 Purge Button 12 Memory Select Button And Location Indicator 8 12 11 3 2 6 5 4 10 9 1 *Dual Feeder Only 7
OM-236 891 Page 54
OM-236 891 Page 55
OM-236 891 Page 56 4-8. Postflow Adjustment Postflow times can be configured for each of the TIG, Wire Feeder Left and Wire Feeder Right outputs. These times are global settings (i.e. all memory slots share the same three postflow settings; it is not possible to set different post- flow times between memory slots). The unit is shipped in the standard configuration (“Std” appears on the display). In the standard configuration postflow times are automatically calculated as follows: For TIG, the postflow time is a function of output current where the minimum time is 8 seconds from 0 to 175 amps and increases linearly form 8 seconds at 175 amps to 16 seconds at 350 amps. For wire processes, the postflow time is a function of wire feed speed where the minimum time is 8 seconds from 0 to 390 ipm and increases linearly for 8 seconds at 390 ipm to 16 seconds at 780 ipm. To adjust postflow time, proceed as follows:
OM-236 891 Page 57 4-9. Wire Feeder Left Side Active Setup Example Only illuminated controls can be changed or adjusted. 1 Left Side Controls Active 2 MIG Process Selected 3 Trigger Hold Off 4 Memory Location 1 Active 4 3 1 2
OM-236 891 Page 58 4-10. Wire Feeder Right Side Active Setup Example (Dual Feeder Only) 4 1 2 3 Only illuminated controls can be changed or adjusted. 1 Right Side Controls Active 2 Pulse Process Selected 3 Trigger Hold On 4 Memory Location 2 Active
OM-236 891 Page 59 4-11. Wire Feeder Non-MIG Setup Example Only illuminated controls can be changed or adjusted. 1 Non-MIG Process Selected 2 Memory Location 3 Active 2 1
OM-236 891 Page 60 4-12. Wire Feeder Timed Purge Example Only illuminated controls can be changed or adjusted. 1 Purge And Trigger Hold Buttons Pressed Simultaneously 2 Purge Time Setting Adjustment Knob 3 Purge Time Remaining Display 1 3 2
OM-236 891 Page 61 4-13. Wire Feeder Auto Jog Example Only illuminated controls can be changed or adjusted. 1 Jog And Trigger Hold Buttons Pressed Simultaneously 2 Jog Feet Adjustment Knob 3 Jog Feet Remaining Display 4 Jog Wire Feed Speed Adjustment Knob 5 Jog Wire Feed Speed Display 1 3 2 4 5
OM-236 891 Page 62 4-14. Basic Parameters For PipeWorx 400 Steel Process Wire Size in. (mm) Wire Feed Speed IPM (mpm) Arc Length Shielding Gas RMD Steel .035 (0.9) 100-350 w/200 Nominal (2.5-8.9 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal
C8 − C15
.035 (0.9) 100-350 w/200 Nominal (2.5-8.9 w/5.1 Nominal) +3.0 to −3.0 w/zero NominalC20 − C25
.035 (0.9) 100-250 w/200 Nominal (2.5-6.4 w/5.1 Nominal) +3.0 to −3.0 w/zero NominalCo2
.045 (1.1) 100-250 w/150 Nominal (2.5-6.4 w/3.8 Nominal) +3.0 to −3.0 w/zero NominalC8 − C15
.045 (1.1) 100-250 w/150 Nominal (2.5-6.4 w/3.8 Nominal) +3.0 to −3.0 w/zero NominalC20 − C25
.045 (1.1) 100-200 w/150 Nominal (2.5-5.1 w/3.8 Nominal) +3.0 to −3.0 w/zero NominalCo2
ProPulse Steel Using A Positioner (Rolling The Pipe) .035 (0.9) 120-780 w/250 Nominal (3.0-19.8 w/6.4 Nominal) +3.0 to −3.0 w/zero NominalC8 − C15
.045 (1.1) 140-500 w/250 Nominal (3.6-12.7 w/6.4 Nominal) +3.0 to −3.0 w/zero NominalC8 − C15
ProPulse Steel Welding In Position .035 (0.9) 120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal) +3.0 to −3.0 w/zero NominalC8 − C15
.045 (1.1) 140-500 w/175 Nominal (3.6-12.7 w/4.4 Nominal) +3.0 to −3.0 w/zero NominalC8 − C15
OM-236 891 Page 63 Stainless Steel Process Wire Size in. (mm) Wire Feed Speed IPM (mpm) Arc Length Shielding Gas RMD Stainless Steel .035 (0.9) 120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal
C2
.035 (0.9) 120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal 98/2 Ox .035 (0.9) 120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal Tri-H .035 (0.9) 120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal Tri-A .045 (1.1) 120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal) +3.0 to −3.0 w/zero NominalC2
.045 (1.1) 120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal) +3.0 to −3.0 w/zero Nominal 98/2 Ox .045 (1.1) 120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal) +3.0 to −3.0 w/zero Nominal Tri-H .045 (1.1) 120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal) +3.0 to −3.0 w/zero Nominal Tri-A
OM-236 891 Page 64 Stainless Steel Process Wire Size in. (mm) Wire Feed Speed IPM (mpm) Arc Length Shielding Gas ProPulse Stainless Steel Using A Positioner (Rolling The Pipe) .035 (0.9) 150-780 w/250 Nominal (3.8-19.8 w/6.4 Nominal) +3.0 to −3.0 w/zero Nominal
C2
.035 (0.9) 150-780 w/250 Nominal (3.8-19.8 w/6.4 Nominal) +3.0 to −3.0 w/zero Nominal 98/2 Ox .035 (0.9) 225-600 w/250 Nominal (5.7-15.2 w/6.4 Nominal) +3.0 to −3.0 w/zero Nominal Tri-H .035 (0.9) 150-780 w/250 Nominal (3.8-19.8 w/6.4 Nominal) +3.0 to −3.0 w/zero Nominal Tri-A .045 (1.1) 120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal) +3.0 to −3.0 w/zero NominalC2
.045 (1.1) 120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal 98/2 Ox .045 (1.1) 140-780 w/200 Nominal (3.6-19.8 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal Tri-H .045 (1.1) 120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal) +3.0 to −3.0 w/zero Nominal Tri-A ProPulse Stainless Steel Welding In Position .035 (0.9) 150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal) +3.0 to −3.0 w/zero NominalC2
.035 (0.9) 150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal) +3.0 to −3.0 w/zero Nominal 98/2 Ox .035 (0.9) 150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal) +3.0 to −3.0 w/zero Nominal Tri-H .035 (0.9) 150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal) +3.0 to −3.0 w/zero Nominal Tri-A .045 (1.1) 120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal) +3.0 to −3.0 w/zero NominalC2
.045 (1.1) 120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal) +3.0 to −3.0 w/zero Nominal 98/2 Ox .045 (1.1) 120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal) +3.0 to −3.0 w/zero Nominal Tri-H .045 (1.1) 120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal) +3.0 to −3.0 w/zero Nominal Tri-A
OM-236 891 Page 65 Flux Core Process Wire Size in. (mm) Rolling Pipe/In Position Wire Feed Speed IPM (mpm) Voltage Shielding Gas Flux Core/GMAW Not Dependent 175-780 w/200 Nominal (4.4-19.8 w/5.1 Nominal)* 24.5-32 w/24.5 Nominal Not Dependent Note: Arc Length − Length of arc from end of wire to weld puddle. Wire feed speed and voltage are synergic for the RMD and ProPulse processes. This means when adjusting wire feed speed, the voltage is automatically adjusted so it is not necessary to adjust the Arc Length. *See wire manufacturer for recommended wire feed speed and gas mixture. 4-15. Lift-Arc™And HF TIG Start Procedures Lift-Arc Start When Lift-Arc button light is On, start arc as follows: 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control (if a remote control is connected). Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. Arc is formed when electrode is lifted. Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid-state output contactor does not energize until after electrode is touching workpiece. This allows electrode to touch workpiece without overheating, sticking, or getting contaminated. Application: Lift-Arc is used for the DCEN or process when HF Start method is not permitted, or to replace the scratch method. HF Start When HF Start button light is On, start arc as follows: High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc. Application: HF start is used for the DCEN GTAW process when a non-con- tact arc starting method is required. 1 1 − 2 Seconds “Touch” Do NOT Strike Like A Match! 2 Lift-Arc Start Method
OM-236 891 Page 66
Section 5 − Maintenance And Troubleshooting
! Disconnect power before maintaining. 5-1. Routine Maintenance = Check = Clean = Replace Every 3 Months Unreadable Labels Weld Terminals Weld Cable Cracked Parts 14-Pin Cord Gas Hose and Fittings Gun Cable Cracked Electrode Holder Parts Cracked Torch Body Every 6 Months Or Inside Unit Drive Rolls 5-2. Blowing Out Inside of Unit ! Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. Ref. 805 142-A
OM-236 891 Page 67 5-3. Restoring Factory Defaults Full System A full factory reset can be accomplished by pressing memory location buttons 1 and 4 on the power source simultan- eously for more than four seconds. The display will show rSt and then go to dashes when the reset is complete. Memory Location See Section 4-2 D2 the reset procedure. 5-4. Viewing Software Revision Pressing the MIG TYPE and SIDE SELECT buttons behind the door on the power source simultaneously will display the Software Revision. 5-5. Power Source Calibration Procedure Only qualified persons should install, operate, maintain, and repair this unit.
A.
Required EquipmentB.
Calibration Procedure
OM-236 891 Page 68
OM-236 891 Page 69 5-6. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460 Volt Models Turn Off welding power source, and disconnect input power. 1 Right Side Panel To remove panel, remove screws securing panel to unit. 2 Relinking Board PC10 3 Voltmeter Measure the dc voltage across the screw terminals on PC10 as shown until voltage drops to near 0 (zero) volts. Proceed with job inside unit. Reinstall right side panel when finished. Tools Needed: 5/16 in. Ref. 805 142-A / Ref. 805 145-A 2 2 3 3 230 VAC input: + lead to lower terminal, − lead to upper terminal 460 VAC input: + lead to lower right terminal, − lead to upper left terminal ! Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit. 1
OM-236 891 Page 70 5-7. Removing Right Side Panel and Measuring Input Capacitor Voltage In 575 Volt Models Turn Off welding power source, and disconnect input power. 1 Right Side Panel To remove panel, remove screws securing panel to unit. 2 Relinking Board PC10 3 Voltmeter Measure the dc voltage across the screw terminals on PC10 as shown until voltage drops to near 0 (zero) volts. Proceed with job inside unit. Reinstall right side panel when finished. Tools Needed: 5/16 in. Ref. 805 142-A / Ref. 805 145-A ! Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit. 2 3 + lead to lower right terminal, − lead to upper right terminal 1
OM-236 891 Page 71 5-8. Cooler Routine Maintenance ! Disconnect cooler plug from welding power source receptacle before maintaining. = Check = Change = Clean Δ = Repair = Replace
OM-236 891 Page 72 5-9. Coolant Maintenance 801 195-A / Ref. 801 194 ! Disconnect cooler plug from welding power source re- ceptacle before maintaining. 1 Cooler Housing 2 Cooler Drawer Remove 4 screws from front of cooler housing and slide cooler drawer out. 3 Coolant Filter Unscrew housing to clean filter and housing. Changing coolant: Drain coolant by tipping unit forward. Fill with clean water and run for 10 minutes. Drain and refill. If replacing hoses, use hoses compatible with ethylene glycol, such as Buna-n, Neoprene, or Hypalon. NOTE: Oxy-acetylene hoses are not compatible with any product containing ethylene glycol. Reinstall cooler drawer into housing. 3 1 2
OM-236 891 Page 73 5-10. Welding Power Source And Feeder Diagnostic Help Codes
H
1 Display Example 0 Display Code Fault DescriptionH01
Primary Power Circuit Over Current Indicates a malfunction in the primary power circuit. If this code appears on the display, contact the nearest Factory Authorized Service Agent.H02
Temperature Sensor Malfunction Indicates thermal protection circuitry is malfunctioning. If this code appears on the display, contact the nearest Factory Authorized Service Agent.H03
Secondary Circuit Over Temperature Indicates left side of unit has overheated. Unit has shutdown to allow fans to lower left side temperature. Operation will continue after unit is within normal temperature range.H04
Secondary Circuit Over Temperature Indicates bottom of unit has overheated. Unit has shutdown to allow fans to lower bottom temperature. Operation will continue after unit is within normal temperature range.H05
Primary Circuit Over Temperature Indicates right side of unit has overheated. Unit has shutdown to allow fans to lower right side temperature. Operation will continue after unit is within normal temperature range.H08
Output Over Voltage Malfunction Indicates secondary power circuit is malfunctioning. If this code appears on the display, contact the nearest Factory Authorized Service Agent.H09
Primary Power Circuit Current Detect Malfunction Indicates primary power circuit is malfunctioning. If this code appears on the display, contact the nearest Factory Authorized Service Agent.H10
Primary Power Circuit Control Malfunction Indicates primary power circuit is malfunctioning. If this code appears on the display, contact the nearest Factory Authorized Service Agent.H11
Primary Bus Capacitor Voltage Imbalance Indicates primary power circuit is malfunctioning. If this code appears on the display, contact the nearest Factory Authorized Service Agent.H12
Primary Input Line Voltage Malfunction Indicates input primary line voltage is too low or power source is incorrectly linked. Increase primary line voltage to at least 90% of specified nominal voltage. Check for correct voltage linking (see Section 3-14).H25
Duty Cycle Indicates duty cycle limit exceeded. Output stops and the cooling fan will run. Wait 15 minutes for unit to cool. Reduce amperage, voltage, wire feed speed, or duty cycle before welding.H26
Button Stuck Power Source Indicates button is stuck on the power source upon start up. Fault will clear when button is released.H30
Stuck Contactor TIG Indicates stuck remote contactor in TIG mode. Fault will clear when foot pedal or control device contactor is released.H31
Stuck Contactor Stick Indicates stuck remote contactor in Stick mode. Fault will clear when foot pedal or control device contactor is released.H40
Tach Left Indicates tach error on left motor. Check left feeder drive housing and wire spool for obstructions. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.H41
Tach Right Indicates tach error on right motor. Check right feeder drive housing and wire spool for obstructions. If this code continues to appear on the display, contact the nearest Factory Author- ized Service Agent.H42
Motor Left Indicates motor error on left motor. Check left feeder drive housing and wire spool for obstructions. If this code continues to appear on the display, contact the nearest Factory Author- ized Service Agent.
OM-236 891 Page 74
H43
Motor Right Indicates motor error on right motor. Check right feeder drive housing and wire spool for obstructions. If this code continues to appear on the display, contact the nearest Factory Author- ized Service Agent.H44
Motor Low Bus Indicates input primary line voltage is too low or power source is incorrectly linked. Increase primary line voltage to at least 90% of specified nominal voltage. Check for correct voltage linking (see Section 3-14). If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.H45
Button Stuck Feeder Indicates button is stuck on the feeder upon feeder power up. Fault will clear when button is released.H46
Trigger Stuck Left Indicates left trigger stuck fault. Fault will clear when left trigger is released.H47
Trigger Stuck Right Indicates right trigger stuck fault. Fault will clear when right trigger is released.H48
Trigger Fault Left Indicates left trigger was held too long in trigger jog (the lesser of 60 seconds or 30 ft (9.1 m) of wire.H49
Trigger Fault Right Indicates right trigger was held too long in trigger jog (the lesser of 60 seconds or 30 ft (9.1 m) of wire.H60
Memory Card Fault Indicates unable to read memory card. Faulty memory card or wrong format.H61
File Read Error Indicates faulty file on memory card.H62
File Write Error Indicates full or faulty memory card.H63
Invalid File Indicates an invalid file on memory card. The system was able to read the file; however, the contents of the file were invalid. Remove card or press any button to clear error.H64
Memory Card Locked Indicates a save was attempted to a locked card. This refers to the physical switch on the memory card. Unlock the memory card and try again. Try a different memory card. Remove card or press any button to clear error. If this code continues to ap- pear on the display, contact the nearest Factory Authorized Service Agent.H65
Read Only File Indicates a save was attempted to a file that has been marked read-only. Check with the appropriate person to see if the attrib- utes are read only for a reason (the attributes can be altered using a PC). Use a different card. Remove card or press any button to clear error.H66
No Memory Card Detected Indicates no memory card detected when a memory card oper- ation was attempted. Insert a card or press any button to clear error. Try a different memory card. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.H70
Weld Library Indicates missing/incomplete weld library in power source. Weld library must be loaded from memory card.H98
Serial Communication Loss Indicates serial communication was initially made and is now malfunctioning. Check wire feeder/power source control cable connection and tighten if necessary. May appear normally dur- ing firmware updates. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.H99
Serial Communication Malfunction Indicates serial communication is malfunctioning. Check wire feeder/power source control cable connection and tighten if necessary. May appear normally during firmware updates. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.
OM-236 891 Page 75 5-11. Troubleshooting Welding Power Source/Wire Feeder Issues If the welding power source and wire feeder are NOT responding after everything is connected, follow the items listed below before contacting the nearest factory-authorized service agent: Welding power source is plugged in and there is no power after turning on unit. If unit is directly connected to a line disconnect box or plugged into a receptacle from a line disconnect box, be sure that the line disconnect switch or main breaker is in the ON position. Wire does not feed from wire feeder to end of gun. Check to see if wire diameter matches the groove size of the drive rolls. Check if tension on drive rolls is too loose or too tight. Check if gun liner is the correct size for the wire size. Check if contact tip is correct size for the wire size, and that end of contact tip is not plugged. Check if gun end is fully inserted into wire drive housing at feeder, and knob is tightened down to secure gun end. Weld is not consistent from one welding application to another. Be sure that work clamp is connected to a clean, paint-free area of pipe; otherwise, grind an area if necessary to make a good work connection. Keep work clamp as close as possible to joint being welded. Check if volt sensing lead is connected to the welding power source and that work connection is secure. Check for any frayed wires at work end of volt sensing lead that may prevent a good connection. Be sure that volt sense lead is separated from weld cables. Be sure gun angle during welding is straight in to 15 degrees back at joint. Follow recommended settings in Operation section of manual to select a starting point for welding. Recommended joint preparation and fit-up is 1/32-1/16 in (0.8-1.6 mm) land and a 1/8 in (3.2 mm) root opening. Refer to Pipe Welding Techniques DVD. Porosity in weld bead. Check shielding gas supply that there is enough gas and supply is turned on. Check shielding gas flow rate at regulator. Check that gas pressure to the wire feeder does not exceed 90 psi (621 kPa). Check all shielding gas fitting and tighten if necessary. Remove gun end from wire drive housing and check condition of O-rings. Replace any worn or missing O-rings. Check power pin end of gun and tighten with a wrench. Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end. Check and clean shielding gas nozzle on gun. Shield joint from wind. Trouble feeding wire when welding. Check drive rolls and wire guides to make sure they match the wire style and size. Check drive roll tension and readjust if necessary. Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end. Check if hub tension at wire spool is too tight or too loose and readjust if necessary. Be sure that welding gun cable is as straight as possible from wire feeder to workpiece. Check if contact tip is correct size for the wire size, and that end of contact tip is not plugged. Check if gun liner is the correct size for the wire size and liner is not dirty or damaged. Clean or replace gun liner if necessary.
OM-236 891 Page 76 5-12. Welding Power Source Troubleshooting Trouble Remedy No weld output; unit completely in- operative. Place line disconnect switch in On position (see Section 3-15). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-15). Check for proper input power connections (see Section 3-15). No weld output; meter display On. Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 3-3). Check voltmeter/ammeter Help displays. Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-18). Clean and tighten all weld connections. Check volt sense lead. Straighten any coiled cables. No 115 volts AC output at single receptacle. Reset supplementary protector CB1 (see Section 3-11). No 24 volts AC output at Remote 14 Feeder receptacle. Reset supplementary protector CB2 (see Section 3-10). When remote control is connected to unit output is always on. Check remote control switch and potentiometer resistances.
OM-236 891 Page 77 ! Disconnect power before troubleshooting. 5-13. Wire Feeder Troubleshooting Trouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check cable connections. Check cables for continuity, and repair or replace cables if necessary. Wire feeder is on, display does not light up, motor does not run, gas valve and welding power source contactor do not pull in. Check and reset circuit breaker at welding power source. Electrode wire feeding stops, or feeds erratically during welding. Check gun trigger connection. See gun Owner’s Manual. Check gun trigger. See gun Owner’s Manual. Readjust hub tension and drive roll pressure (see Section 3-26). Change to correct size drive roll (see Table 9-1). Clean or replace dirty or worn drive roll. Incorrect size or worn wire guides. Replace contact tip or liner. See gun Owner’s Manual. Remove weld spatter or foreign matter from around nozzle opening. Have Factory Authorized Service Agency check drive motor or motor control board PC1. Motor runs slowly. Check for correct input voltage. Wire feeder displays light up, feeder jogs, purges, but unit is inoperative. Check welding gun trigger leads for continuity, and repair leads or replace gun. When triggered, wire feeds but no gas, no contactor. If the welding arc does not establish in 2 seconds after the gun trigger is activated the unit will feed wire, but turns off contactor and gas valve. If the gun trigger is still activated after 60 seconds or 30 ft (9.1 m) of wire was fed from the gun, the wire will stop feeding.
OM-236 891 Page 78 ! Disconnect power before troubleshooting. 5-14. Cooler Troubleshooting Trouble Remedy Coolant system does not work. Be sure input power cord is plugged into energized receptacle. Check supplementary protector CB1 at welding power source, and reset if necessary. Motor overheated. Unit starts running when motor has cooled. Have Factory Authorized Service Agent check motor. Decreased or no coolant flow. Add coolant. Check for clogged hoses or coolant filter. Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
OM-236 891 Page 79 Notes
OM-236 891 Page 80
Section 6 − Electrical Diagram
Figure 6-1. Circuit Diagram For Welding Power Source
OM-236 891 Page 81
234 105-F
OM-236 891 Page 82 Figure 6-2. Circuit Diagram For Single Or Dual Wire Feeder
OM-236 891 Page 83
236 220-E
OM-236 891 Page 84 Figure 6-2. Circuit Diagram For Cooler
238 662-A
OM-236 891 Page 85 Figure 6-3. Flow Diagram For Cooler Pump Filter Radiator Flow Indicator Tank Torch
OM-236 891 Page 86
Section 7 − Parts List
Hardware is common and not available unless listed.805 149-B
1 6 7 8 2 3 4 5 9 10 11 80 14 17 18 19 20 21 34 31 23 33 24 25 26 27 28 29 30 36 37 40 39 38 41 42 35 43 75 76 77 78 43 44 45 46 47 63 62 48 50 52 51 53 54 55 56 57 59 60 61 58 65 69 64 66 82 83 67 71 72 74 73 84 86 79 85 81 87 91 89 88 95 92 94 93 80 22 32 49 70 90 37 13 16 68 96 96 97 15 12 Figure 7-1. Main Assembly
OM-236 891 Page 87 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Model 907 382 907 384 1 +233480
Panel,Rear
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Cb2
093995Supplementary Pro,Man Reset 1P 15A 250Vac Frict
1 1 . . . . . . . . . . . . . . . . . . 3Pc11
233919Circuit Card Assy,Ps/Feeder Interface
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 228036Valve, 24Vac 1Way .750−14 Thd 2.0Mm Orf 100 Psi
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 236638Hose,Nprn Brd No 1 X .187 Id X 40.000
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 220805Nut, 750−14 Nps 1.48Hex .41H Nyl
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 010467Conn,Clamp Cable 1.250
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 181181Label,Warning Match Input Power To Voltage
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 237163Label,Mig Output
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237157Label,Cb2
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238560Label,Tig Gas In
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237158Label,To Wirefeeder
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C3, C4,
. . . .C5, C6
192935Capacitor,Elctlt 2700 Uf 450 Vdc Can 2.52 Dia
4 . . . . . . . . . . . . . 9C3, C4,
. . . .C5, C6
193738Capacitor,Elctlt 1800 Uf 500 Vdc Can 2.52 Dia
4 . . . . . . . . . . . . . . . . . . . . 218004Label,Warning Electric Shock/Exploding Parts
3 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217040Nut,Nylon M12 Thread Capacitor Mounting
4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Pc4
184180Circuit Card Assy,Interconnecting
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Pc4
186873Circuit Card Assy,Interconnecting
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 185214Bus Bar,Interconnecting 575
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Pc10
234712Circuit Card Assy,Relink 230/460
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 +233486Panel,Side Rh 230/460
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 +240841Panel,Side Rh 575
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 237155Label,Important Input Power/Relink Connections 1
. . . . . . . . . . . . . . . . . . . 15 222317Label,Warning Match Input Power
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 234271Sheet,Insulator Side Panel
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Fm1, Fm2
222728Fan,Muffin 24Vdc 3000 Rpm 255 Cfm
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 233501Bracket,Fan
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19L1
180026Inductor,Input
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windtunnel,Rh W/Cmpnts (Includes)
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 030170Bushing,Snap−In Nyl .750 Id X 1.000 Mtg Hole
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 025248Stand−Off,Insul .250−20 X 1.250 Lg X .437 Thd
4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22W1
180270Contactor,Def Prp 40A 3P 24Vac Coil W/Boxlug
1 1 . . . . . . . . . . . . . . . . . . . . . . 23Ct1
233620Xfmr,Current 500 Turn Polarized
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 177547Bushing,Snap−In Nyl Ct−Mount 1.125 Mtg Hole
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 010493Bushing,Snap−In Nyl .625 Id X .875 Mtg Hole
4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 233462Windtunnel,Rh
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Pm1, Pm2
240144Kit,Transistor Igbt Module
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 179930Heat Sink,Power Module
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Rt1
173632Thermistor,Ntc 30K Ohm @ 25 Deg C 12.00In Lead
1 1 . . . . . . . . . . . . . . . . . . . . . . 30Sr1
183334Rectifier,Integ Bridge 130. Amp 1600V 3Ph
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31C1, C2
230272Capacitor,Polyp Film .34 Uf 1000 Vrms +/−10%
2 . . . . . . . . . . . . . . . . . . 31C1, C2
230270Capacitor,Polyp Film .22 Uf 1000 Vrms +/−10%
2 . . . . . . . . . . . . . . . . . . . . . . . . . 32L2
233438Inductor,Output
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33L3, L4
233617Inductor,Di−Dt
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 218566Gasket,Inductor Mounting E70 Ferrite Core
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Cb1
083432Supplementary Pro,Man Reset 1P 10A 250Vac Frict
1 1 . . . . . . . . . . . . . . . . . . 36Rc2
134837Rcpt,Str Grd 2P3W 15A 125V Single *5−15R
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 170647Bushing,Snap−In Nyl 1.312 Id X 1.500 Mtg Hole
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Hd1
168829Transducer,Current 1000A Module
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 234358Base, W/ Pem Nuts
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 229325Foot,Mtg Unit
4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 88 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Model 907 382 907 384 41 210866
Terminal,Pwr Output Black
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Pc6
237704Circuit Card Assy,Remote Interface
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 182665Terminal,Pwr Output Neutral
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 210865Terminal,Pwr Output Red
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 236968Overlay,Secondary Panel
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 231191Switch,Tgl 3Pst 50A 600Vac Scr Term Wide Tgl
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176226Insulator,Switch Power
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 120854Ftg,Gas
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 237415Hose,Gas Braided 5 In
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 236596Plate,Switch
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 241087Cover,Output Stud W/Labels (Includes)
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238574Label,Connection Secondary Panel
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238535Label,Pipeworx 400
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Pc3
233887Circuit Card Assy,Ui W/Program Ps
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 234496Overlay,Power Source
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 174991Knob,Pointer 1.250 Dia X .250 Id W/Spring Clip−.21
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 54 236828Door,Bezel,Mig Setup
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 234497Bezel,Power Source
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 236830Door,Sd Reader
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 234344Bracket,Sd Card Reader
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Pc12
236041Circuit Card Assy,Sd Card
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 236748Whiteboard,Magnetic
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 233479Panel,Front
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212810Label,On−Off W/Symbols
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windtunnel,Lh W/Cmpnts (Includes)
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 233910Heat Sink,Power Module
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62D1, D2,
. . . .D3, D4
235029Diode,Ultra−Fast Recovery 300A 600V Dual
4 4 . . . . . . . . . . . . . . . . . . . 63 233490Bus Bar,Diode
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 233461Windtunnel,Lh
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 057358Bushing,Snap−In Nyl 1.000 Id X 1.375 Mtg Hole
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Rt2
222327Thermistor,Ntc 30K Ohm @ 25 Deg C 24.00In Lead 1
1 . . . . . . . . . . . . . . . . . . . . 67 232296Resistor/Capacitor Assy
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 233911Windtunnel Bottom, W/ Pem Nuts
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69T1
233413Xfmr,Hf 230/460 Unit
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69T1
236304Xfmr,Hf 575 Unit
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Scr1,
. . . . .Scr2, Scr3
234711Thyristor,Scr Module 500A 800V Single
3 3 . . . . . . . . . . . . . . . . . . . .Rt3,Rt4
234339Thermistor,Ntc 30K Ohm @ 25 Deg C 12.00In Lead
2 2 . . . . . . . . . . . . . . . . . 71 234056Heat Sink,Scr Polarity Switching
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 234279Bus Bar,Scr
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73T3
233909Xfmr,Hf Arc Start
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 179848Boot,Positive Output Stud
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 180735Washer,Output Stud
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windtunnel,Top Assy (Includes)
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 234280Baffle,Windtunnel
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 233476Windtunnel,Top
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 233489Bracket,Capacitor Support
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 216366Bushing,Snap−In Nyl .500 Id X .625 Mtg Hole
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170647Bushing,Snap−In Nyl 1.312 Id X 1.500 Mtg Hole
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057358Bushing,Snap−In Nyl 1.000 Id X 1.375 Mtg Hole
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216596Strap,Grounding 4.50 In Long
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 89 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Model 907 382 907 384 80 233485
Panel,Side Lh
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 134327Label,Warning General Precautionary Static
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 233483Cover,Top
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 233488Frame,Lifting
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 026627Gasket,Lifting Eye Cover
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236749Bracket,Mtg Circuit Cards Assy (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236778Bracket,Mtg Circuit Cards Assy (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Pc9
233732Circuit Card Assy,Secondary Gate Driver
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 233892Bracket,Mtg Circuit Cards
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Pc1
233468Circuit Card Assy,Process Control W/Program
1 1 . . . . . . . . . . . . . . . . . . . . 88Pc2
233463Circuit Card Assy,Inverter Control W/Program
1 . . . . . . . . . . . . . . . . . . . . . 88Pc2
236631Circuit Card Assy,Inverter Control W/Program
1 . . . . . . . . . . . . . . . . . . . . . . . 198122Stand−Off Support,Pc Card .250W/Post&Lock
10 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 236299Choke,Common Mode
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236770Bracket,Mtg Xfmr Assy (Includes)
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 233478Bracket,Mtg Xfmr
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 198122Stand−Off Support,Pc Card .250W/Post&Lock
4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Pc5
236096Circuit Card Assy,Hf Arc Starter
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93T2
236645Xfmr,Control 230/460 Vac Pri 1589Va 60 Hz
1 . . . . . . . . . . . . . . . . . . . . . . . . . 93T2
236646Xfmr,Control 575 Vac Pri 1589Va 60 Hz
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 057358Bushing,Snap−In Nyl 1.000 Id X 1.375 Mtg Hole
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 219076Core,Ferrite 22Mm Od X 10Mm Id X 33Mm Lg
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96C7,8,11
236678Capacitor Assy
3 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 C15,16,17
247825Capacitor Assy
3 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 90
805 300-A
Hardware is common and not available unless listed. 1 3 6 7 8 9 10 11 12 13 15 16 17 19 21 23 22 14 4 18 20 26 24 25 27 2 5 Figure 7-2. Cooler Description Part No. Dia. Mkgs. Item No. Figure 7-2. Cooler Quantity 1 173263Motor,1/4Hp 115Vac 50/60Hz 1425/1725 Rpm Dual
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 134795Coupler,Drive Pump
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 173999Pump,Coolant
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 094263Clamp,1−Ear Type Nom Dim .718 X .276 Wide
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236814Assy,Fan/Radiator (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5523Fitting
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 232424Radiator,Heat Exchanger
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 213072Plenum,Air
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 231341Fan,Muffin 115V 60Hz 3400 Rpm 6.378 Mtg Holes
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 236813Base,W/Pem Studs
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 236845Side,Cooler Base
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 236846Panel,Rear Cooler Base
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 +236844Shell,Cooler Base W/Pem Nuts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 203990Label,Warning General Precautionary Static
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 229325Foot,Mtg Unit
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 91 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Cooler Quantity 15 173955
Tank,Water
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 166608Cap,Tank Screw−On W/Vent
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Panel Assy,W/Cmpnts (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 +236810Panel,Front W/Pem Studs
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 219178Label,Caution Incorrect Coolant
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 081543Ftg,Coolant
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 238664Light,Ind Wht Lens 125Vac Snap−In Neon Non−Relampa
1 . . . . . . . . . . . . . . . . . . . . . . . 233159Spacer,Nylon .312 Od X .194 Id X .500 Lg
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 215279Indicator,Flow
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 188082Cable,Power 2 Ft 7 In 16Ga 3C
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204603Label,Coolant Out
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204604Label,Coolant In
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 236815Bracket,W/Filter (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 236816Bracket,Tank Top
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 166564Filter,In−Line Low Profile 100 Screen 3/8 Hose Bar
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 26 178461Bracket,Filter
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 239494 SCREEN,FILTER LP CYL 100x100x0.0045 SST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228529Hose,Rubber Braided .375 Id X .650 Od X 19.500
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237152Hose,Rubber Braided .375 Id X .650 Od X 22.500
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237416Hose,Coolant Braided 10 In
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 92 Hardware is common and not available unless listed.
805 152-A
1 2 3 4 5 7 8 9 1011 12 13 1211 10 14 15 16 6 25 26 27 17 18 19 21 22 24 40 28 29 32 33 34 36 37 38 39 23 42 41 20 30 35 31 − Figure 7-5 Figure 7-3. Single Wire Feeder
OM-236 891 Page 93 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Single Wire Feeder Quantity 1 +234243
Wrapper,Single Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 134464Label,Warning General Precautionary Static&Wire Fe
1 . . . . . . . . . . . . . . . . . . . .Panel Assy,Pcb Support (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 236556Panel,Pc Board Support
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198122Stand−Off Support,Pc Card .250W/Post&Lock .500
7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Pc1
233967Circuit Card Assy,Pipeworx Feeder Mtr Ctrl
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 5 010494Bushing,Snap−In Nyl 1.375 Id X 1.750 Mtg Hole
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 143160Hub+Spindle Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 058427Ring,Retaining Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 180573Shaft Assy,Support Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 010233Spring,Cprsn .970 Od X .120 Wire X 1.250 Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 057971Washer,Flat .632Idx1.500Odx.125T Stl Pld .175Key
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 010191Washer,Flat .656Idx1.500Odx.125T Fbr
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 058628Washer,Brake Stl
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 058428Hub,Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 071730Tubing,Stl .875 Od X12Ga Wall X 2.500
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 135205Nut, 625−11 .94Hex .77H Stl Pld Elastic Stop Nut
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 200556Support,Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 233559Base,Feeder W/Pem Nuts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 134306Foot,Rubber 1.250 Dia X 1.375 High No 10 Screw
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 238518Label,Single Feeder Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Panel,Front W/Cmpnts Single Bench Feeder (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Pc2
233899Circuit Card Assy,Ui W/Program Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 236261Overlay,Single Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 234501Bezel,Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 213134Knob,Encoder 1.670 Dia X .250 Id Push On W/Spring
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 233560Panel,Front
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Plug Assy,Trigger Lh (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg17
115093Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rc2
048282Rcpt W/Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Plug Assy,Remote (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rc4
222857Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg35
115093Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200822Housing Plug+Pins,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 000527Blank,Snap−In Nyl .875 Mtg Hole Black
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 159647Insulator,Motor Clamp
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 159360Insulator,Screw Machine
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 125473Hose,Sae .187 Id X .410 Od X 27.000
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 201762Drive Assy,Wire S/L 4 Roll W/Tach
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 145639Strip,Buna−N .062 X 3.000 X 4.000 Compressed Sht
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 156243Clamp,Motor Top
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 234426Knob,W/Extension (Lh) Clamp
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 159646Clamp,Motor Base
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 94 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Single Wire Feeder Quantity
Rear Panel Assy,Single Feeder (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Pc3
233919Circuit Card Assy,Ps/Feeder Interface
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Gs1
228036Valve, 24Vac 1Way .750−14 Thd 2.0Mm Orf 100 Psi
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 38 220805Nut, 750−14 Nps 1.48Hex .41H Nyl
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 211989Fitting,W/Screen
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 030170Bushing,Snap−In Nyl .750 Id X 1.000 Mtg Hole
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 239737Receptacle,Banana Jack Blk 10−32 Binding Post
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 238498Enclosure,Rear Single Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 074481Label,Left
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106410Label,To Power Source
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215467Label,Volt Sense
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151026Kit,Drive Roll .035 V−Gr 4 Roll
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 95 Hardware is common and not available unless listed.
805 150-A
1 3 2 4 5 6 7 8 7 6 5 9 10 11 12 16 17 18 19 21 26 25 24 27 28 32 33 35 36 37 40 42 44 43 38 38 39 39 15 23 22 20 34 29 14 13 13 30 − Figure 7-5 31 − Figure 7-5 41 Figure 7-4. Dual Wire Feeder
OM-236 891 Page 96 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Dual Wire Feeder Quantity 1 142838
Bracket,Mtg Spool Rh
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 143160Hub+Spindle Assy
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 135205Nut, 625−11 .94Hex .77H Stl Pld Elastic Stop Nut
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 071730Tubing,Stl .875 Od X12Ga Wall X 2.500
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 057971Washer,Flat .632Idx1.500Odx.125T Stl Pld .175Key
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 010191Washer,Flat .656Idx1.500Odx.125T Fbr
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 058628Washer,Brake Stl
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 058428Hub,Spool
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 010233Spring,Cprsn .970 Od X .120 Wire X 1.250 Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 180573Shaft Assy,Support Spool
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 058427Ring,Retaining Spool
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 141411Support,Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 211989Fitting,W/Screen
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 239737Receptacle,Banana Jack Blk 10−32 Binding Post
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 030170Bushing,Snap−In Nyl .750 Id X 1.000 Mtg Hole
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 233559Base,Feeder W/Pem Nuts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 134306Foot,Rubber 1.250 Dia X 1.375 High No 10 Screw
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 238513Label,Dual Feeder Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Panel,Front W/Cmpnts Dual Bench Feeder (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Pc2
233899Circuit Card Assy,Ui W/Program
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 234500Overlay,Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 234501Bezel,Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 213134Knob,Encoder 1.670 Dia X .250 Id Push On W/Spring
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 233560Panel,Front
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Plug Assy,Trigger Lh (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg17
115093Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rc2
048282Rcpt W/Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Plug Assy,Remote (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rc4
222857Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg35
115093Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200822Housing Plug+Pins,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Plug Assy,Trigger Rh (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L 2
213030Core,Toroidal 19.00Mm Id X 29.01Mm Od X 7.62Mm Th
1 . . . . . . . . . . . . . . . . . . . . . . . .Plg16
115093Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rc3
048282Rcpt W/Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 159647Insulator,Motor Clamp
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 159360Insulator,Screw Machine
8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 125473Hose,Sae .187 Id X .410 Od X 27.000
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 201762Drive Assy,Wire S/L 4 Roll W/Tach
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 201768Drive Assy,Wire R 4 Roll W/Tach
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 145639Strip,Buna−N .062 X 3.000 X 4.000 Compressed Sht
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 156243Clamp,Motor Top
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 159646Clamp,Motor Base
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 234424Knob,W/Extension (Rh) Clamp
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 234426Knob,W/Extension (Lh) Clamp
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 97 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Dual Wire Feeder Quantity
Rear Panel Assy,Dual Feeder (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Pc3
233919Circuit Card Assy,Ps/Feeder Interface
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 233561Enclosure,Rear Dual Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Gs 1,
. . . . .Gs 2
228036Valve, 24Vac 1Way .750−14 Thd 2.0Mm Orf 100 Psi
2 . . . . . . . . . . . . . . . . . . . 39 220805Nut, 750−14 Nps 1.48Hex .41H Nyl
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 074479Label,Right
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 074481Label,Left
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106410Label,To Power Source
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215467Label,Volt Sense
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 +233562Wrapper,Dual Feeder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 134464Label,Warning General Precautionary Static&Wire Fe
1 . . . . . . . . . . . . . . . . . . . .Panel Assy,Pcb Support (Includes)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 236556Panel,Pc Board Support
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198122Stand−Off Support,Pc Card .250W/Post&Lock .500
7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 010494Bushing,Snap−In Nyl 1.375 Id X 1.750 Mtg Hole
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Pc1
233967Circuit Card Assy,Pipeworx Feeder Mtr Ctrl
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 237210Hose Assy,Gas Y
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143838Cable,Weld 26 In 4/0 W/Terms
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151026Kit,Drive Roll .035 V−Gr 4 Roll
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151053Kit,Drive Roll .045 Vk−Gr 4 Roll
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 98 See Table 7-1 For Drive Roll & Wire Guide Kits Hardware is common and not available unless listed.
803 790-A
20 11 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 1 2 3 4 5 6 22 21 19 18 17 16 15 14 19 13 12 11 9 10 8 7 6 5 4 3 2 1 Figure 7-5. Drive Assembly, Wire Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-5. Drive Assembly, Wire (Figure 7-3 Item 31 And Figure 7-4 Items 30 And 31) 1 010 668 Screw, Cap Stl Sch .250-20 X 1.500 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 Carrier, Drive Roll W/Components 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 149 962 Spacer, Carrier Drive Roll 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 149 486 Pin, Rotation Arm Rocker 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 132 750 Arm, Pressure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 150 520 Spacer, Flat Stl .257 Id X .619 Od X .105 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 133 493 Ring, Retaining Ext .250 Shaft X .025Thk 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 133 350 Pin, Hinge 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M1,101
201 230 Motor, Gear 1/8hp 24VDC Standard Speed 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 491 Kit, Brush Replacement (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 492 Cap, Brush 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *153 493 Brush, Carbon 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 136 Kit, Brush Holder Replacement 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 155 098 Kit, Cover Motor Gearbox (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 550 Cover, Motor Gearbox (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 099 Gasket, Cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 100 Screw, Cover 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 031 Spacer, Locating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 493 Ring, Rtng Ext .250 Shaft Grv X .025Thk 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-236 891 Page 99 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-5. Drive Assembly, Wire (Continued) 203 642 Pressure Arm, R & Vert L 4 Roll (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 631 Pressure Arm, S/L & Vert S/R 4 Roll (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 203 641 Washer, Flat Indicator Spring Tension 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 182 415 Pin, Cotter Hair 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 203 640 Knob, W/Extension Short Pressure Arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 182 156 Spring, Cprsn 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 182 155 Spring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 132 746 Bushing, Spring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 203 633 Shaft, Spring 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 203 632 Carrier, Shaft 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 133 739 Washer, Flat Buna .375 Id X .625 Od X .062Thk 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 203 637 Knob, W/Extension Long Pressure Arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pc51,151
237 048 Circuit Card Assy, Digital Tach (Includes) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg5
131 204 Connector & Sockets 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604 311 Grommet, Rbr .250 Id X .375Mtg Hole .062 Groove 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 132 611 Optical Encoder Disc 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603 115 Weather Stripping, Adh .125 X .375 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 167 387 Spacer, Locating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 168 825 Drive, Pinion 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 133 308 Ring, Retaining Ext .375 Shaft X .025Thk 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 134 834 Hose, Sae .187 Id X .410 Od (order by ft) 2 Ft (0.6 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 149 959 Fitting, Brs Barbed M 3/16Tbg X .312-24 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 179 265 Adapter, Gun/Feeder LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 179 264 Adapter, Gun/Feeder RH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 108 940 Screw, Cap Stl Hexhd .250-20 X .750 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 604 538 Washer, Flat Stl Sae .312 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 151 437 Knob, Plstc T 1.125 Lg X .312-18 X 1.500 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 151 290 Screw, Mach Stl Hexwhd 10-32 X .500 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 179 277 Cover, Drive Roll (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 937 Label, Warning Electric Shock 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 601 872 Nut, Stl Hex Full Fnsh .375-16 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 602 213 Washer, Lock Stl Split .375 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 602 243 Washer, Flat Stl Std .375 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 601 966 Screw, Cap Stl Hexhd .375-16 X 1.250 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Recommended Spare Parts. 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-236 891 Page 100 Table 7-1. Drive Roll And Wire Guide Kits Wire Size Inlet Guide Intermediate Guide
V-Groove
Vk-Groove
Fraction Metric 4 Roll Kit Drive Roll 4 Roll Kit Drive Roll .035 in. 0.9 mm 150 993 149 518 151 026 053 700 151 052 132 958 .045 in. 1.1/1.2 mm 150 994 149 519 151 027 053 697 151 053 132 957 .052 in. 1.3/1.4 mm 150 994 149 519 151 028 053 698 151 054 132 956 1/16 in. (.062 in.) 1.6 mm 150 995 149 520 151 029 053 699 151 055 132 955 .068-.072 in. 1.8 mm 150 995 149 520 151 056 132 959 5/64 in. (.079 in.) 2.0 mm 150 995 149 520 151 057 132 960 3/32 in. (.094 in.) 2.4 mm 150 996 149 521 151 058 132 961 Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along With 4 Drive Rolls.
OM-236 891 Page 101 Hardware is common and not available unless listed. 805 302-b 12 1 3 4 7 8 9 9 10 11 2 5 6 5 Figure 7-6. Running Gear
OM-236 891 Page 102 Description Part No. Dia. Mkgs. Item No. Figure 7-6. Running Gear Quantity 1 236827
Handle,Power Source
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 238611Cap,Tube .865 Od
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 236817Handle,Gun Holder Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 +233666Bracket,Support Cylinder Dual
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200285Label,Warning Cylinder May Explode If Damaged
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 170647Bushing,Snap−In Nyl 1.312 Id X 1.500 Mtg Hole
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 004214Bushing,Snap−In Nyl 1.625 Id X 2.000 Mtg Hole
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 188441Chain,Weldless 2/0 X 31. Bright Zinc Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 234359Rack Wheel Assy, Running Gear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 602250Washer,Flat .812Idx1.469Odx.134T Stl Pld Ansi.750
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 121614Ring,Rtng Ext .750 Shaft X .085 Thk E Style Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 163463Wheel,Rbr Tire 10.000 Od X 2.000 Wide X .750 Bore
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 209479Caster,Swvl 5.00 In Urethane W/Brake 2.000 In Wide
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-236 891 Page 103 805 301-A / Ref. 239 780-B Hardware is common and not available unless listed. 8 1 2 3 4 5 6 7 4 4 9 Figure 7-7. Composite Cables Quantity Description Part No. Dia. Mkgs. Item No. 25 ft 50 ft Figure 7-7. Composite Cables Model 300 454 300 456 5 ft 300 367 1 300508
Cable,Interconnecting 5 Ft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 300465Cable,Interconnecting 31 Ft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 300466Cable,Interconnecting 56 Ft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 238108Hose Assy,Gas 33 Ft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 238109Hose Assy,Gas 58 Ft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 238110Cable,Weld 4.5 Ft 2/0 W/Terms
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 238111Cable,Weld 31 Ft 2/0 W/Terms
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 238112Cable,Weld 56 Ft 2/0 W/Terms
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 238432Clamp,Strain Relief
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 238263Cover,Cable 28 Ft (Black)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 238264Cover,Cable 53 Ft (Black)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 210253Cable Tie, 0−1.750 Bundle Dia
2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 047636Housing Plug + Pins,(Service Kit)
2 2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 143922Conn,Circ Cpc Clamp Str Rlf
2 2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 300461Cable,Volt Sense
1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 300462Cable,Volt Sense
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +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-236 891 Page 104 Hardware is common and not available unless listed.
805 148-B
1 3 2 Figure 7-8. Cable Hanger Assembly Description Part No. Dia. Mkgs. Item No. Figure 7-8. Cable Hanger Assembly Quantity 1 285304Bracket,Cable Holder W/Edge Trim
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 238611Cap,Tube .865 Od
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 236826Tube,Cable Holder
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-236 891 Page 105
805 318-A
Hardware is common and not available unless listed. 8 1 2 3 4 5 6 7 9 10 13 11 12 14 15 Figure 7-9. Feeder Cart
OM-236 891 Page 106 Description Part No. Dia. Mkgs. Item No. Figure 7-8. Cable Hanger Assembly Quantity 1 217255
Slide,Drawer
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 234505Handle Assy, Feeder Cart
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 234546Tab,Lift Slot
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 234554Shelf,Upper,Feeder Cart
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 235121Holder,Cable Gun
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 234556Leg,Rear Rh Cart
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 234553Axle,Cart
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 163463Wheel,Rbr Tire 10.000 Od X 2.000 Wide X .750 Bore
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 602250Washer,Flat .812Id X 1.469Od X .134T Stl Pld
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 121614Ring,Rtng Ext .750 Shaft X .085 Thk E Style Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 234545Shelf,Lower,Feeder Cart
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 123557Caster,Swvl 5.00 In Polyolefin X 1.375 X .437−14
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 234555Leg,Rear Lh Cart
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 237215Bracket,Drawer Lh
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 232470Drawer,Assy
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.
Warranty Questions? Call
1-800-4-A-Miller
for your local Miller distributor. miller_warr 2010−01 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, 2010 (Equipment with a serial number preface of MA 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. THISWarranty 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 delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.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.
Original Instructions − Printed In Usa
© 2010 Miller Electric Mfg. Co. 2010−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to: For Service Owner’s Record File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. Contact your Distributor for:To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller