Download Miller Electric 452 Owner`s manual

OM-203 860C
October 2002
Processes
Gas Metal Arc (MIG) Welding
Description
Arc Welding Power Source
Auto Deltaweld
452
Visit our website at
www.MillerWelds.com
R
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
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 orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual:
Mig = GMAW
WARNING
This product, when used
for welding or cutting,
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.)
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. 115 VAC Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Upper Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Short Circuit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Front Panel Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Weld Interface Board PC12 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Diagnostic LED’s On Weld Interface Board PC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Customer Interface Board PC14 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Diagnostic LED’s On Customer Interface Board PC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Motor Board PC13 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Diagnostic LED’s On Motor Board PC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_7/02
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y 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 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-203 860 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-203 860 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
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.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D 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 electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-203 860 Page 3
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800–463–6727 or in Toronto 416–747–4044, website: www.csa–international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212–642–4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269–9101 (phone: 617–770–3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (phone:
617–770–3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202–4102 (phone: 703–412–0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
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, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices––phone for Region 5, Chicago, is
312–353–2220, website: www.osha.gov).
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-203 860 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SÉCURITÉ – À LIRE AVANT
UTILISATION
som _nd_fre 7/02
1-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 1–4.
Lire et respecter toutes ces normes.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur–le–
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi–automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre–vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé – tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé–sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-203 860 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer 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 agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte–
électrode ou couper le fil au raz du tube–contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-203 860 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
D
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte–bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression – elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P–1 de la CGA,
mentionnées dans les normes de sécurité.
1-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au–dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables.
D 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’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-203 860 Page 7
1-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443–9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463–6727 ou à Toronto : (416) 747–4044, site Web : www.csa–international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443–9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036–8002 (téléphone : (212) 642–4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269–9101 (téléphone : (617) 770–3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (téléphone : (617) 770–3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P–1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202–4102 (téléphone : (703) 412–0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
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 l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux – Téléphone pour la Région 5, Chicago : (312)
353–2220, site Web : www.osha.gov).
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-203 860 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 2 – INSTALLATION
2-1. Specifications
Rated
Welding
Output
Model
450 Amp
450 A @ 38
(36.5) Volts
DC, 100%
Duty Cycle
Voltage
Range DC
Max OCV
DC
10 – 38
48
Amperes Input at Rated Load Output, 50 or 60 Hz,
Three-Phase
200 V
230 V
380 V
400 V
440 V
460 V
575 V
KVA
KW
72
3.2*
63
2.7*
39
2.6*
37
2.2*
33
2.1*
32
1.4*
25
1.1*
25.1
1.09*
21.1
0.26*
*While idling
2-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
RATED OUTPUT
WELD AMPERES
1000
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.
800
600
Y Exceeding duty cycle can
damage unit and void
warranty.
400
300
40
50
60
70
80
90
100
% DUTY CYCLE
100% Duty Cycle
Continuous Welding
Overheating
V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / Ref. 168 918
OM-203 860 Page 9
2-3. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
va_curve1 – 4/95 – 171 224 / 171 225 / 171 226
2-4. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
Rating Label
Use rating label to determine input
power needs. Label located under
front access door.
OR
2
4
Line Disconnect Device
Locate unit near correct input power supply.
Location And Airflow
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
4
3
18 in
(460 mm)
18 in
(460 mm)
OM-203 860 Page 10
802 962
2-5. Dimensions And Weights
Dimensions
A
A
C
B
30 in (762 mm) Including lift eye
B
23 in (584 mm)
C
38 in (965 mm) Including strain
relief
D
35 in (889 mm)
E
1-1/4 in (32 mm)
F
21-1/8 in (537 mm)
G
1-1/8 in (29 mm)
H
7/16 in (11 mm) Dia
F
G
H
4 Holes
D
Weight
E
545 lb (247 kg)
Front
800 453-A / 801 530
2-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
OM-203 860 Page 11
2-7. 115 VAC Receptacle And Circuit Breakers
Y Turn Off power before connecting to receptacle.
1
115 V 15 A AC Receptacle
RC9
Power is shared between RC9 and
Remote 14 receptacle RC8.
3
2
3
2
Circuit Breaker CB1
Circuit Breaker CB2
CB1 protects the 115 volts ac portion of RC8 and RC9 from overload.
CB2 protects the 24 volts ac portion
of RC8.
1
Press button to reset breaker.
Ref. 800 166-D
2-8. Connection Diagram
5
2
. The proper robot adapter cord
must be connected to the
interface unit to allow it to be
connected to the robot.
3
4
1
1
6
13
11
7
8
12
9
Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
6 Robot Input/Output Cable
7 Remote Program Select
Cable (Optional)
8 Gas And Motor Control Cable
9 Welding Power
Source/Interface Unit
10 Negative (–) Weld Cable
11 Workpiece
12 Voltage Sensing Lead
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
13 Positive (+) Weld Cable
10
802 963
OM-203 860 Page 12
2-9. Weld Output Terminals And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
Y Turn off power before
connecting to weld output terminals.
Y Do not use worn, damaged, undersized, or poorly
spliced cables.
Negative
Positive
High
Inductance
Positive
Low
Inductance
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 – 60%
Duty Cycle
60 – 100%
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
700
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
10 – 100% Duty Cycle
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for
the mm2 equivalent weld cable sizes.
S-0007-E
OM-203 860 Page 13
2-10. Electrical Service Guide
60 Hertz Models
450 Amp Model
Input Voltage
200
230
460
575
Input Amperes At Rated Output
72
63
32
25
90
70
40
30
110
90
45
40
4
6
8
10
163
(50)
142
(43)
366
(112)
379
(115)
6
8
10
10
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2
Normal Operating 3
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
50 Hertz Models
450 Amp Model
Input Voltage
380
400
440
Input Amperes At Rated Output
39
37
33
Time-Delay 2
45
45
40
Normal Operating 3
60
50
50
8
8
8
250
(76)
277
(84)
335
(102)
10
10
10
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
OM-203 860 Page 14
2-11. Placing Jumper Links
Y Disconnect and lockout/tagout input power before
installing or moving jumper
links.
Check input voltage available at
site.
1
Jumper Link Label
Check label – only one is on unit.
2
Jumper Links
Move jumper links to match input
voltage.
Close access door, or go on to
Section 2-12.
200 VOLTS
230 VOLTS
460 VOLTS
Ref. S-174 976-A
230 VOLTS
460 VOLTS
575 VOLTS
1
Ref. S-174 973-A
220 VOLTS
380 VOLTS
400 VOLTS
440 VOLTS
(FACTORY OPTION)
Ref. S-174 975-A
2
Tools Needed:
3/8 in
Do not overtighten
jumper link nuts.
3/8 in
Ref. ST-800 103-A
OM-203 860 Page 15
2-12. Connecting Input Power
Y Disconnect and lockout/tagout input power before connecting input
conductors from unit.
Y Have only qualified persons make
this installation.
= GND/PE Earth Ground
See rating label on unit and check input
voltage available at site.
1
1
2
3
9
Select size and length using Section 2-10.
Conductors must comply with national,
state, and local electrical codes. If applicable, use lugs of proper amperage capacity
and correct hole size.
8
4
Strain Relief
Route conductors through strain relief.
4
7
5
6
3
When making connections in
the line disconnect device,
connect the Green Or
Green/Yellow conductor first.
Machine Grounding Terminal
Line Terminals
Y Make input power connections to
the welding power source before
making connections into a deenergized line disconnect device.
Connect green or green/yellow grounding
conductor to machine grounding terminal
first. Then connect input conductors to line
terminals.
Install conductors into
a deenergized line
disconnect device.
IMPORTANT
6
Make connections
to machine first and
supply last.
3
Input Contactor
Close access door.
7
8
Disconnect Device (Supply)
Grounding Terminal
Disconnect Device Line Terminals
Y In the deenergized line disconnect
device, connect green or green/yellow grounding conductor to supply grounding terminal first, never
to a line terminal. Be sure grounding conductor goes to an earth
ground.
L1 (U)
2 L2 (V)
L3 (W)
3
10
Line Disconnect Device
Input Conductors
Grounding Conductor
Connect input conductors to line terminals.
3
9
5
GND/ PE Connect Green Or Green/Yellow
GND/PE Conductor First.
Overcurrent Protection
Select type and size using Section 2-10
(fused disconnect switch shown).
Close door on line disconnect device.
10 Reed Switch (Ground Current
Sensor) (Optional)
If unit is equipped with optional ground current sensor, route grounding conductor
through reed switch two times and connect to ground terminal.
Tools Needed:
3/8 in
Close access door.
3/8 in
ST-800 103-B / Ref. ST-801 116
OM-203 860 Page 16
2-13. Front Panel Connections
1
2
B
C
A
M
L
K
J
P NT
R S
D
E
FG
H
Example Receptacle
5
6
3
4
Ref. S-0003-A / Ref. 203 394
1
Receptacle
cord to work.
2
Keyway
4
3
4-Pin Receptacle (Optional External
Voltage Sensing Connection)
To connect interconnecting cord to receptacle, align keyway, insert plug, and tighten
threaded collar.
Secure ring terminal on remaining end of
Peripheral Receptacle
Receptacle provides connection to water
flow switch, jog +/–, and shielding gas
purge circuitry.
5
Robot Control Receptacle (Remote
Program Select Connection To Robot
Control)
To connect matching interconnecting cord
to one of the above receptacles, align keyway, insert plug, and tighten threaded collar. Connect remaining end of cord to
matching receptacle on applicable equipment (see Section 2-8).
6 10-Socket Receptacle (Wire
Feed/Shielding Gas Control
Connection To Motor Drive
Assembly)
OM-203 860 Page 17
2-14. Peripheral Receptacle Functions
Function
A
Circuit common.
D
Contact closure to C completes 24 volts dc
solenoid circuit to purge shielding gas line.
E
Contact closure to F indicates coolant flow switch is
closed and recirculating coolant system is
operational.
F*
Circuit common.
Jog +
H**
Contact closure to circuit common advances
welding wire at wire drive assembly.
Jog –
J**
Contact closure to circuit common retracts welding
wire at wire drive assembly.
Coolant Flow
Switch Input
Signal
K
J
M
C
L
D
H
E F
Rer. 203 394
*Circuit common is same electrical reference point.
**Speed of Jog + and Jog – defaults to 200 ipm.
Note: A matching amphenol plug is supplied with a flow switch jumper.
OM-203 860 Page 18
Socket Information
C*
Purge
B
Socket
SECTION 3 – OPERATION
3-1. Upper Front Panel Controls
7
8
9
1
1 Jog Forward Push Button
Advances wire out of the gun.
2 Wirefeed Indicator LED
LED lights when wire feed motor is
energized.
3 Jog Reverse Push Button
Retracts wire up into the gun.
4
2
Gas Indicator LED
LED lights when gas solenoid is energized.
5
Purge Push Button
Momentarily energizes gas solenoid to
purge air from gun shielding gas line, or to
adjust shielding gas regulator.
6
Contactor Indicator LED
3
4
5
6
LED lights when welding power source
contactor is energized.
7 Main Display
Shows system state, error messages, commands at idle and actual feedback during
welding.
8 Motor Circuit Breaker
9 High Temperature Shutdown Light
Ref. 203 394
3-2. Meter Functions
Mode
Meter Reading At Idle
V
MIG
24.5V
Command Volts
Meter Reading While Welding
IPM
0I
Command WFS
V
24.5V
Actual Volts
A
0A
Actual Amps
IPM
0I
Actual WFS
OM-203 860 Page 19
3-3. Resetting Memory
2
1
Front Panel Control Buttons
Power Switch On Front Panel
. All three buttons must be held
Jog Reverse
Button
Jog Forward
Button
1
2
down for 3 seconds after unit is
energized.
Purge
Button
Press and hold down all three
buttons while turning On unit.
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Replace
damaged or
unreadable
label.
Repair or
replace
cracked
cables.
Replace
cracked
torch body.
Repair or
replace cracked
cables and cords.
6 Months
Clean and
tighten weld
terminals.
OM-203 860 Page 20
Blow out
inside.
4-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 800 453-A
4-3. Fuse F1
Y Turn Off power before opening rear access door.
1
2
Fuse Holder Cover
Fuse F1 (See Parts List For
Rating)
Fuse F1 protects control transformer from overload. If F1 opens, weld
output and fan motor stops. Replace F1.
2
1
Tools Needed:
3/8 in
Turn
Pull Out And Replace Fuse
(Install Flat End Of Fuse Into Cover)
Turn
Ref. 800 101-C
4-4. Short Circuit Shutdown
When contact tip is shorted and sticks to workpiece, the unit output falls to a safe operating level. To resume operation,
release gun trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged.
Turn On unit to continue operation.
OM-203 860 Page 21
4-5. Front Panel Error Displays
7
1
Mem
CRC
S t o p
E r r o r
2
Mem
R a n g e
E r r
N o
V o l t
S e n s e d
E r r o r
1
D e t e c t e d
C u r r e n t
D e t e c t
10
T a c h
S e n s e d
E r r o r
W i r e
S t i c k
E r r o r
11
S t o p
E r r o r
A r c
6
A r c
F l o w
G r d
5
A r c
E r r
9
4
N o
C y c l e
8
3
N o
We l d
F a i l
T i me O u t
E r r
12
S t a r t
E r r o r
Memory CRC Error Display
Corrupted program data has been detected
or loaded. The “X” value indicates the program number.
N o
I n p u t
The motor tachometer feedback is not
reaching the control.
May be caused by obstructions in the wire
feed system or a faulty wire drive system.
Ground Current Detect Error Display
Weld current has been detected in the earth
ground connection.
May be caused by a conductor making
connection to the unit chassis.
May be caused by incompatible information
on the data card or bad memory.
5
2
May be caused by obstructions in the wire
feed system or a faulty wire drive system or
torch is touching part at end of weld.
The welding wire has stuck to the workpiece
at the end of the weld.
6
May be caused by poor weld conditions.
Memory Range Error Display
Improper welding power source range is
selected. The “X” value indicates the program number.
May be caused by improper range settings
or improper data loaded into the interface
unit.
3
No Volt Sensed Error Display
The arc voltage sense circuit did not receive
feedback within the required time after an arc
was established.
May be caused by an inability to establish an
arc in the pulse schedule, or a lack of voltage
feedback.
4
No Tach Sensed Error Display
OM-203 860 Page 22
Arc Stop Error Display
9
I PM
Trouble is occurring at arc end.
Arc Start Error Display
10 Wire Stick Error Display
Trouble is occurring at arc start.
11 Arc Fail Time Out Error Display
May be caused by obstructions in the wire
feed system or a faulty wire drive system.
An arc was not established within the allotted
time.
7
May be caused by an inoperable wire drive,
absence of shield gas, or improperly operating welding power source.
Stop Weld Cycle Error Display
An error has been detected and the robot
hasn’t stopped the weld cycle, causing the
interface unit to stop the weld cycle and wait
for the robot to stop.
8
No Flow Detected
No coolant is detected after preflow in the
weld cycle. Check coolant system and flow
switch for proper operation.
12 No Input IPM Display
Analog IPM (inches per minute) from robot is
not being received.
May be caused by having no wire feed speed
programmed at the robot.
4-6. Weld Interface Board PC12 Diagnostic LED’s
1
Weld Interface Board PC12
Diagnostic LED’s are visible inside
unit, located on PC12 (see illustration
for board location).
LED2
LED8
LED4
LED6
LED1
LED3
LED5
LED7
Refer to Section 4-7 for information
on diagnostic LED’s.
LED10
LED9
LED11
Reinstall cover and left side panel
after checking diagnostic LED’s.
LED12
1
LED13
Front
Top View
191 842 / 802 996
OM-203 860 Page 23
4-7. Diagnostic LED’s On Weld Interface Board PC12
LED
Status
1
On
Indicates auxiliary output relay is not energized.
Off
Indicates auxiliary output relay is energized.
On
Indicates gas valve is not energized.
Off
Indicates gas valve is energized.
3
On
Indicates +24 volts dc is present for gas valve.
Off
Indicates +24 volts dc is not present for gas valve.
4
On
Indicates +15 volts dc is present on weld interface board PC12.
Off
Indicates +15 volts dc is not present on weld interface board PC12.
On
Indicates –15 volts dc is present on weld interface board PC12.
Off
Indicates –15 volts dc is not present on weld interface board PC12.
6
On
Indicates +15 volts dc power source supply is present on weld interface board PC12.
Off
Indicates +15 volts dc power source supply is not present on weld interface board PC12.
7
On
Indicates –15 volts dc power source supply is present on weld interface board PC12.
Off
Indicates –15 volts dc power source supply is not present on weld interface board PC12.
On
Indicates +5 volts dc is present on weld interface board PC12.
Off
Indicates +5 volts dc is not present on weld interface board PC12.
9
On
Input signal for no Jog retract.
Off
Input signal for Jog retract.
10
On
Input signal for no Jog advance.
Off
Input signal for Jog advance.
On
Indicates CV mode is selected.
Off
Indicates CC mode is selected.
On
Input signal for no welding power source contactor.
Off
Input signal for welding power source contactor.
On
Indicates an Emergency Stop condition is not present.
Off
Indicates an Emergency Stop condition is present.
2
5
8
11
12
13
OM-203 860 Page 24
Diagnosis
4-8. Customer Interface Board PC14 Diagnostic LED’s
1
Customer Interface Board PC14
Diagnostic LED’s are visible inside
unit, located on PC14 (see illustration
for board location).
Refer to Section 4-9 for information
on diagnostic LED’s.
Reinstall front control panel after
checking diagnostic LED’s.
LED8
LED6
LED7
1
LED12
LED16
LED14
LED23
LED10
LED9
LED15
LED25
LED22
LED11 LED13
LED24
LED5
LED4
LED21
LED20
LED19
LED18
LED3
LED17
LED2
LED1
Front Control
Panel Removed
Front View
802 995
OM-203 860 Page 25
4-9. Diagnostic LED’s On Customer Interface Board PC14
LED
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Status
Diagnosis
On
Indicates –15 volts dc RA supply is present on customer interface board PC14.
Off
Indicates –15 volts dc RA supply is not present on customer interface board PC14.
On
Indicates +15 volts dc RA supply is present on customer interface board PC14.
Off
Indicates +15 volts dc RA supply is not present on customer interface board PC14.
On
Input signal On from robot for no Emergency Stop.
Off
Input signal Off from robot for Emergency Stop.
On
Indicates +24 volts dc RD supply is present on customer interface board PC14.
Off
Indicates +24 volts dc RD supply is not present on customer interface board PC14.
On
Input signal On from robot for shielding gas.
Off
Input signal Off from robot for no shielding gas.
On
Input signal On from robot to energize contactor.
Off
Input signal Off from robot to not energize contactor.
On
Input signal On from robot for jog retract.
Off
Input signal Off from robot for no jog retract.
On
Input signal On from robot for jog advance.
Off
Input signal Off from robot for no jog advance.
On
Indicates automatic configuration Bit D is set.
Off
Indicates automatic configuration Bit D is not set.
On
Input signal On for RPS-C.
Off
Input signal Off for RPS-C.
On
Input signal On for RPS-B.
Off
Input signal Off for RPS-B.
On
Indicates remote program A selected.
Off
Indicates remote program A not selected.
On
Input signal On from peripheral for touch sensor.
Off
Input signal Off from peripheral for no touch sensor.
On
Indicates automatic configuration Bit B is set.
Off
Indicates automatic configuration Bit B is not set.
On
Indicates automatic configuration Bit A is set.
Off
Indicates automatic configuration Bit A is not set.
On
Indicates automatic configuration Bit C is set.
Off
Indicates automatic configuration Bit C is not set.
On
Input signal On from relay CR4 for wire stuck in weld joint.
Off
Input signal Off from relay CR4 for wire not stuck in weld joint.
On
Input signal On from relay CR6 for flow (shielding gas or coolant) present.
Off
Input signal Off from relay CR6 for flow (shielding gas or coolant) not present.
On
Input signal On from relay CR5 for arc detect.
Off
Input signal Off from relay CR5 for no arc detect.
On
Input signal On from relay CR2.
Off
Input signal Off from relay CR2.
On
Input signal On from relay CR1 for welding power source ready and no detected errors present.
21
Off
Input signal Off from relay CR1 for welding power source not ready, detected errors are present, or unit
is in Setup or Control mode.
22
On
Input signal On from peripheral for flow switch.
Off
Input signal Off from peripheral for no flow switch.
20
OM-203 860 Page 26
LED
Status
23
On
Input signal On from peripheral for jog advance.
Off
Input signal Off from peripheral for no jog advance.
On
Input signal On from peripheral for jog retract.
24
25
26
Diagnosis
Off
Input signal Off from peripheral for no jog retract.
On
Input signal On from peripheral for shielding gas purge.
Off
Input signal Off from peripheral for no shielding gas purge.
On
Input signal On for touch sensor.
Off
Input signal Off for no touch sensor.
OM-203 860 Page 27
4-10. Motor Board PC13 Diagnostic LED’s
1
LED2 LED1
Motor Board PC13
Diagnostic LED’s are visible inside
unit, located on PC13 (see illustration
for board location).
1
Refer to Section 4-11 for information
on diagnostic LED’s.
Reinstall front control panel after
checking diagnostic LED’s.
LED4
LED3
LED6
LED7
LED8 LED5
Front Control
Panel Removed
Front View
177 288 / 802 995
OM-203 860 Page 28
4-11. Diagnostic LED’s On Motor Board PC13
LED
Status
1
On
Indicates motor reverse relay is energized.
Off
Indicates motor reverse relay is not energized.
On
Indicates bus voltage is present.
Off
Indicates bus voltage is not present.
On
Indicates microprocessor is operational.
Off
Indicates microprocessor is not operational.
On
Indicates tachometer feedback signal is present.
Off
Indicates tachometer feedback signal is not present.
On
Indicates +5 volts dc is present on motor board PC13.
Off
Indicates +5 volts dc is not present on motor board PC13.
On
Indicates +15 volts dc is present on motor board PC13.
Off
Indicates +15 volts dc is not present on motor board PC13.
On
Indicates auxiliary forward signal is present.
Off
Indicates auxiliary forward signal is not present.
On
Indicates auxiliary output signal is present.
Off
Indicates auxiliary output signal is not present.
2
3
4
5
6
7
8
Diagnosis
OM-203 860 Page 29
4-12. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 2-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-11)).
Check for proper input power connections (see Section 2-11).
Check fuse F1, and replace if necessary (see Section 4-3).
Check for proper jumper link position (see Section 2-11).
No weld output; Power switch pilot light
on; fan on; meter display On.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 2-2).
Check voltmeter/ammeter Help displays.
Unit overheated. Allow unit to cool with fan On (see Section 2-2).
Have Factory Authorized Service Agent check control board PC1.
Unit provides only maximum or minimum weld output.
Have Factory Authorized Service Agent check control board PC1.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 2-9).
Clean and tighten all weld connections.
Have Factory Authorized Service Agent check control board PC1 and/or SCR in main rectifier.
Fan not operating. Note: fan runs only
when cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
OM-203 860 Page 30
SECTION 5 – ELECTRICAL DIAGRAM
. For Primary Circuit Diagram Portion, refer to Circuit Diagram
located inside wrapper of welding power source.
207 810-B
Figure 5-1. Circuit Diagram For Welding Power Source
OM-203 860 Page 31
Figure 5-2. Circuit Diagram For Interface Module
OM-203 860 Page 32
207 811-A
OM-203 860 Page 33
Figure 5-3. Circuit Diagram For Control Board PC1 (Part 1 Of 2)
OM-203 860 Page 34
208 198-1 (1 0f 2)
OM-203 860 Page 35
208 198-2 (2 of 2)
Figure 5-4. Circuit Diagram For Control Board PC1 (Part 2 Of 2)
OM-203 860 Page 36
Notes
OM-203 860 Page 37
Figure 5-5. Circuit Diagram For Microprocessor Board PC11
OM-203 860 Page 38
191 838
OM-203 860 Page 39
Figure 5-6. Circuit Diagram For Motor Board PC13
OM-203 860 Page 40
209 749
OM-203 860 Page 41
Figure 5-7. Circuit Diagram For Interface Board PC12 (Part 1 of 2)
OM-203 860 Page 42
191 843-A (Part 1 of 2)
OM-203 860 Page 43
Figure 5-8. Circuit Diagram For Interface Board PC12 (Part 2 of 2)
OM-203 860 Page 44
191 843-A (Part 2 of 2)
OM-203 860 Page 45
1
+35V
L2
R6
470
+22VDC
WBC
1W 5% MF
1
1
1
D1
C16
22uF
35V
+
C6
470uF
+
1N4746A
18V
C64
50V
330pF
100V
2
2
TP8
1
2
C12
.033uF
400V
2
2
2
1
+
1
C14
1uF
50V
CER
1
1
2
2
R69
1
FB
2
1
Q1
IRF640
10
6
OUTPUT
1
RT/CT
2
1
.2 Ohms rds–on
3
5
GND
D3
1
4
UC3813D–5 \ UC
TP2
PRLL5819
3845D
TP3
2
C5
330pF
100V
+ C11
1uF
50V
CER
R65
1
TP1
R3
2
7
VCC
I_SENSE
.1uF
50V
8
VREF
C8
2
1
2
COMP
Z3
HEATSINK1
1
.1uF
50V
U1
1
3
1
5% 1/4W
2
2
SMT
22K
SMT
47
2
22K
2
R5
1
R68
2
TP4
TP5
22
C7
2
1
44.2K
1%
+
2
R4
SMT
2
C10
1uF
50V
CER
1
C9
100pF
1
1
+22VDC
C4
2
1uF
50V
CER
Figure 5-9. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3)
OM-203 860 Page 46
1
1
+
R1
0.06
2
1
1
R66
100K
1%
2
C63
330pF
100V
1
1K
1%
2
2
R2
2
NON–INDUCTIVE
MF
1W
+20V_UNREG
U3
LM340T–15
50V
C67
.1uF
50V
2
2
C65
.1uF
50V
1
R71
2.21K
R72
2.21K
2
+
100uF
2
C19
TP7
470uF
50V
BEAD
2
IN
3
OUT
C68
.1uF
50V
RA–15V
1
2
LED2
YELLOW
SMT
1
1
50V
C2
2
+
+
1
1
1
2
L3
100uF
2
1
BYJ20J
1.5A
600V
C18
U2
GND
2
7
C66
.1uF
50V
2
1
2
D8
3
TP6
2
RAGND
1
RA–15V
1
RA+15V
1
GND
C3
470uF
50V
BEAD
2
9
8
2
2
BYJ20J
1.5A
600V
+
1
1
1
RA+15V
1
10
L4
2
2
D4
2
3
OUT
1
T1
XFRMR – MULTI–OUTPUT
IN
1
1
RAGND
LED1
YELLOW
SMT
RAGND
LM7915CT
6
–20V_UNREG
+24RD
L5
1
1
+
50V
2
RD_GND
2
2
1
PRELOAD
TL431
TP39
LED4
YELLOW
SMT
1
RD_GND
R89
Z1
2.21K
FUSE CLIP
Z2
FUSE CLIP
4
RD_GND
3
2
1
PC817
TL431AI
TP29
1
8
R14
44.2K
1%
2
R20
162K
1%
D2
2
1
1
TP30
1
2
C29
.01uF
6
R10
4.99K
C26
2
2
+22VDC
C34
100uF
R999
330
U4
C73
.1uF
50V
2
1A
2
R74
2.21K
+
1
1
1
C33
470uF
50V
2
BEAD
2
1
1
BYJ20J
600V
1.5A
1
1
RD_GND
2
2
F1
2
D7
1
220pF
RD_GND
1kV
C15
2
1
RAGND
220pF
1kV
Pensar 86147 (Part 1 of 3)
OM-203 860 Page 47
RAGND
RA+15V
2
2
C75
.1uF
50V
3
4
6
4
4
3
+
2
–
R79
44.2K
1%
RAGND
AGND
1
1
C25
2
.1uF
50V
2
+15V
AGND
TP41
TP51
2
5
+
6
U13B
LM358
7
1
R91
100
1%
1
–
3
C28
.1uF
50V
+
9
–
R17
44.2K
1%
8
U7C
LM324A
4
RAGND
1
R28
44.2K
1%
AGND
AGND
C39
2
.1uF
50V
1
RN3
100K–ADJ
3
2
1
2
R19
12.1K
1%
RA+15V
2
2
6
4
1
1
1
2
R30
44.2K
1%
10
2
+15V
C79
.01uF
100V
U12
TIL–300
5
2
1
R93
221K
1%
2
1
1
AGND AGND
8
2
C41
100uF
50V
2
1
+
1
1
2
1
2
.1uF
50V
C32
C83
.1uF
50V
RA+15V
AGND
+15V
1
2
1
+15V
U14A
LM324A
AGND
C84
.1uF
50V
2
+15V
2
1
+15V
C86
.1uF
50V
2
TP64
1
AGND
C46
.1uF 50V
2
1
–
C44
.1uF
50V
6
+
3
–
2
2
AGND
AGND
–15V
TP57
RN5
1
3
R31
12.1K
1%
RAGND
2
C45
.1uF
50V
R39
44.2K
1%
11
1
U9
5
8
4
1
3
6
1
–
RA+15V
4
7
1
2
2
R96
100
1%
U8A
LM358
+ 3
4
TIL–300
RAGND
+15V
C35
1
2
AGND
.1uF
50V
1
AGND
1
2
C50
.1uF
50V
2
1
R32
100K
1%
RA+15V
–15V
2
1
2
2
1
R36
100K
1%
2
–
2
1
4
3
1
8
1
WFS_CMD
+
U14B
LM324A
+ 5
100K–ADJ
2
1
C48
.1uF
50V
C47
.1uF 50V
1
TP49
C51
.1uF
50V
C82
AGND
AGND
–
8
–
13
RA+15V
9
R35
44.2K
1%
5
U10
RN6
1
3
R34
12.1K
1%
100K–ADJ
2
1
3
6
7
TIL–300
AGND
–
6
RA+15V
4
+15V
U8B
LM358
5
RAGND
2
C43
.1uF
50V
+
8
U14C
LM324A
10
1
14
+
1
2
U14D
LM324A
+ 12
4
1
1
TP48
2
.1uF
50V
2
R97
100
1%
1
AGND
1
2
6
2
1
–
1
R33
100K
1%
2
7
5
4
TRI M_CMD
+
R37
100K
1%
2
TP65
TP58
2
+15V
U15B
LM358
2
2
RAGND
2
C37
1
.1uF
50V
1
C49
.1uF
50V
Figure 5-10. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3)
OM-203 860 Page 48
C74
.1uF
50V
RAGND
TP61
TP50
U15A
LM358
8
2
1
GND
RN4
100K–ADJ
3
2
2
.1uF
50V
C42
+15V –15V
C40
100uF
50V
1
U7A
LM324A
2
RA+15V
1
DGND
+
GND
+
RA–15V
RA–15V
R13
12.1K
1%
+5V
C53
C89 100uF
50V
.1uF
50V
C23
.1uF
50V
1
R27
44.2K
1%
2
2
2
2
2
R29
44.2K
1%
AGND
+5V
1
5
–
1
1
C80
.01uF
100V
2
GND
1
RAGND
U11
TIL–300
1
R92
100
1%
+15V
1
AGND
–15V
U13A
LM358
+
11
3
+5V
CON\2X5\MILLER
VCC
AGND
TP45
2
1
R94
221K
1%
1
RA+15V
C72
.1uF
50V
2
DGND
TP40
1
+15V
+15V
C77
.1uF
50V
AGND
8
1
6
2
7
3
8
4
9
5
10
2
2
RC97
+5V
1
1
1
+15V
2
TP35
RA+15V
Q3
MMBT4401L
3
2
R70
100
1%
D12
1
1
2
1
2
–
7
R83
1K
1%
RAGND
2
TP28
+
C13
680uF
25V
TP37
U7B
LM324A
2
6
RLS4148
1
+
1
5
TP15
RA+15V
TP18
Q2
MMBT4401L
3
2
R67
100
1%
D5
1
1
2
1
2
14
+
C1
680uF
25V
TP19
U7D
LM324A
2
–
1
+
13
RLS4148
1
12
R75
1K
1%
2
RAGND
K1
6
4
8
RELAY DPDT (MDX24–02)
11
K1_COMMON
13
9
RD_GND
1
16
2
+24RD
1
2
D13
DL4001
R12
10K
1%
2
TP23
2
D10
RLS4148
LF347D
1 R18
R87
221K
1 1%
LF347D
2
2
3
RAGND
RA+15V
5.11K
2
1
RA–15V
RLS4148
TP26
7
1
D9
RLS4148
4
1 R84
R24
221K
1 1%
2
2
5
U6C
8
LF347D
9
10
1
1
R78
100K
1%
LF347D
RAGND
2
R81
100K
1%
C70
.1uF
50V
RAGND
RAGND
RAGND
RAGND
RD_GND
RAGND
2
5.11K
2
RAGND
RA–15V
RN2
100K–ADJ
2
RA+15V
1
11
2
12
3
13
4
14
5
15
6
16
7
17
8
18
9
19
10
20
RA+15V
RAGND
2
CON\2X10\MILLER
R76
100K
1%
U6D
12
+
13
–
R73
14
2
1
TP17
LF347D
1
2
100K
1%
+ C17
.47uF
50V
1
R80
100K
1%
1
TP31
6
3
TP27
2
RA+15V
2
R77
100K
1%
R82
100K
1%
TP9
2
3
2
2
TP22
1
1
RC93
2
U6B
1
2
TP14
R16
100K
1%
Pensar 86147 (Part 2 of 3)
RAGND
1
U6A
11
RA–15V
1
2
2
C31
.1uF 50V
2
1
2
1
+
RAGND
TP12
2
C30
.001uF 100V
2
1
–
1
2
LF347D
R22
44.2K
1%
1
D6
+
1
R86
221K
1%
R8
10K
1%
R9
10K
1%
1
2
TP16
C22
.1uF
50V
–
TP36
C38
.01uF
100V
TP32
RAGND
+
2
C71
.1uF
50V
1
TP38
2
C24
.1uF
50V
RAGND
RAGND
R26
44.2K
1%
2
R85
100K
1%
2
TP25
1
2
RAGND
1
RAGND
RA–15V
R88
100K
1%
1
R11
100K
1%
C20
.1uF
50V
2
–
LF347D
RA+15V
1
+
12
1
–
14
13
1
1
TP20
RN1
100K–ADJ
U5D
TP11
C69
.1uF
50V
11
1
3
RAGND
5
1
1
6
4
1
1
10
7
2
2
C36
.01uF
100V
9
2
RAGND
RA–15V
U5A
LF347D
U5B
8
+
2
R23
44.2K
1%
U5C
2
–
R25
44.2K
1%
1
R21
221K
1%
+
1
R7
100K
1%
1
–
TP34
RAGND
2
C27
.001uF 100V
2
1
TP33
RA+15V
TP13
TP10
2
2
2
RLS4148
1
1
1
D11
R15
10K
1%
1
C21
.1uF 50V
2
1
TP24
2
1
+
TP21
–
1
LED3
GREEN
SMT
RAGND
OM-203 860 Page 49
TP101
12
1
1
1
1
1
1
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
2
2
2
2
2
2
1%
1
2
3
4
5
6
9
8
11
10
13
12
74HC1 4
1
2
3
4
+5V
5
6
1
OC12
TP119
A4
4
9
2
1
3
OC11
GND
A5
4
TP112
C5 7
.1uF
50V
C5 2
.1uF
50V
8
2
1
1
TP120
+5V
1
+5V
C5 5
.1uF
50V
AB_SEL
10 !AB_SEL
11
13
12
2
AIN4
B0
B1
B2
B3
B4
B5
B6
B7
TP83
TP76
TP70
TP66
TP59
TP53
TP46
TP42
R4 4 R4 3 R4 5 R4 7 R4 2 R4 0 R3 8 R4 1
10K
1%
1% 1% 1% 1% 1% 1%
2
C9 5
.1uF
50V
TP122
1
GND
10
U1 6
LED16
SMT
RED
2
1
R116
1
2
2.21K
1%
8
U1 8
2
3
TP124
1
C9 6
.1uF
50V
AIN3
6
9
74HC1 4
2
2
1
1
A3
4
5
13
+5V
4
1
2
TP126
+24RD
TP128
2
3
11
2
1
2.21K
1%
A2
1%
1
GND
3
2
1
LED22
RED SMT
R119
+24RD
GND
4
OC13
1
TP131
2
TP130
OC14
2
TP129
1
C9 7
.1uF
50V
AIN2
R120
1
2
2.21K
1%
+24RD
1
LED23
RED
SMT
2
A1
3
1
A0
A1
A2
A3
A4
A5
A6
A7
GND
4
2
2
AIN1
TP133
OC15
TP134
R5 8 R5 5 R5 2 R5 1 R5 4 R5 7 R4 8 R4 6
10K
1%
1% 1% 1% 1% 1% 1%
2
2
3
1
1
1
2.21K
1%
+24RD
TP132
A0
4
2
LED24
SMT
RED
2
1
C9 8
.1uF
50V
R121
OC16
1
2
TP136
U2 2
+5V
1
+24RD
TP135
LED25
SMT
RED
2
1
C9 9
.1uF
50V
AIN0
R6 3
1
2
2.21K
1%
2
2
GND
3
1
C9 4
.1uF
50V
TP117
2
1
OC9
GND
74HC1 4
4
A6
3
GND
4
A7
TP85
TP91
2
AIN5
OC10
GND
GND
TP113
1
1
R113
1
2
2.21K
1%
+24RD
LED15
RED SMT
C9 3
.1uF
50V
TP107
3
2
GND
2
AIN6
TP103
1
1
+24RD
LED14
SMT
RED
2
1
R109
2.21K
1%
2
R106
2.21K
1
1%
TP96
LED13
SMT
RED
2
1
2
C9 2
.1uF
50V
AIN7
2
RC100
TP92
1
BIN_SINK1
BIN_SINK4
BIN_SINK2
RD_GND
BIN_SINK3
BIN_SINK5
AIN4
BIN_SINK6
AIN5
TP84
TP86
1
R102
2.21K
1%
BIN_SINK1
B0
3
OC7
4
GND
B1
1
2
1
3
OC6
4
GND
B2
BIN_SRC3
BIN_SRC5
AIN4
BIN_SRC6
AIN5
RD_GN D
AIN6
BIN_SRC7
RD_GN D
BIN_SRC0
RD_GN D
1
2.21K
1%
+24RD
2
LED10
RED
SMT
2
3
2
1
TP71
1
C8 8
.1uF
50V
TP74
2
4
GND
B3
3
GND
2
BIN_SINK2
OC5
1
R101
LED9
RED
2
BIN_SINK3
+24RD
U1 9
2 R103
2 R118
2 R115
2 R114
2 R117
2 R112
2 R110
TP125
TP118
TP80
1
2
3
4
5
6
7
8
I1
I2
I3
I4
I5
I6
I7
GND
RD_GND
O1
O2
O3
O4
O5
O6
O7
V+
16
15
14
13
12
11
10
9
R9 9
1
2
2.21K
1%
TP63
1
LED8
RED SMT
2
1
C8 5
.1uF
50V
BIN_SINK4
C8 1
.1uF
50V
ULN2003
B4
OC3
4
GND
B5
TP60
2
1
3
OC2
1
4
GND
B6
3
OC1
4
GND
B7
TP54
SMT
2
3
1
2
BIN_SINK5
4
3
2
LED7
RED
2
R9 8
1
2
2.21K
1%
TP56
+24RD
OC4
2
1
10K
1%
1
2
TP87
TP127
TP123
TP121
1
C8 7
.1uF
50V
TP68
RD_GN D
TP67
SMT
1
R100
1
2
2.21K
1%
+24RD
CON\2X8\MILLER
1
1
1
1
1
1
1
1
4
TP77
C9 0
.1uF
50V
TP79
OC8
2
2
BIN_SRC1
BIN_SRC4
BIN_SRC2
LED11
SMT RED
2
2
+24RD
RD_GN D
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
16
1
BIN_SINK0
2
RD_GND
RC110
1
2
RD_GND
BIN_SINK0
CON\2X8\MILLER
BIN_SRC0
BIN_SRC1
BIN_SRC2
BIN_SRC3
BIN_SRC4
BIN_SRC5
BIN_SRC6
1
R105
2.21K
1%
+24RD
RD_GN D
AIN6
BIN_SINK7
LED12
SMT
RED
2
1
C9 1
.1uF
50V
1
RD_GND
1
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
16
2
+24RD
TP52
3
2
+24RD
R9 0
1
2
2.21K
1%
2
R107
2.21K
1%
BIN_SINK6
Q4
MMBT4401L
1
RD_GN D
RD_GND
TP47
1
1
C7 8
.1uF
50V
SMT
2
R108
12.1K
1%
2
LED6
RED
2
BIN_SINK7
TP44
LED5
RED
2
C7 6
.1uF
50V
TP43
SMT
1
1
1
1
BIN_SRC7
+24RD
R9 5
1
2
2.21K
1%
2
TP97
Figure 5-11. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3)
OM-203 860 Page 50
GND
TP111
TP106
TP102
TP100
TP94
TP89
!AB_SEL
2
1
+5V
A1
A2
A3
A4
A5
A6
A7
A8
19
1
1
2
3
4
5
6
7
8
9
10
AB_SEL
G
DIR
10K TP116
1%
R111
18
17
16
15
14
13
12
11
B1
B2
B3
B4
B5
B6
B7
B8
WFS_CMD
TRIM_CMD
11
12
13
14
15
16
17
18
19
20
ARC_DET
WLDR_RDY
SPARE
FLOW_ERR
STK_ERR
TOUCH_SENSOR
20 PIN AMP–LATCH
74H C245
TP82
TP110
+5V
TP78
TP72
TP62
TP69
TP55
+5V
R104
1
A1
A2
A3
A4
A5
A6
A7
A8
19
1
2
+5V
1
U1 7
2
3
4
5
6
7
8
9
18
17
16
15
14
13
12
11
B1
B2
B3
B4
B5
B6
B7
B8
C5 6
.1uF
50V
2
TP75
1
TP73
C5 4
.1uF
50V
2
TP90
RC98
U2 0
2
3
4
5
6
7
8
9
TP95
GND
GND
RC94
G
DIR
10K
1%
!AB_SEL
AIN0
AIN1
TP81
C5 8
.001uF
100V
1
LED26
GREEN
1SMT
2
2
R6 1
2.67M
1
R6 0
150
U2 3
4N 32
R
R6 2
6
10K
1%
5
2
CON\3X3\MILLE
1
1
1
AIN3
AIN7
AIN2
+24RD
4
TP138
2
TP137
2
RD_GN D
1
R6 4
1K
1%
Q5
2
3
2
RD_GN D
+5V
4
1
7
5
2
8
6
3
9
RD_GN D
RD_GN D
74H C245
MMBT4401L
1
K1_COMMON
1
2
10K
2
R122
RD_GND
RC96
K5
RELAY_COM
6
NCA_SPARE
8
NOA_SPARE
11
NCB_SPARE
4
RD_GN D
L1
13
+35V
TP93
R4 9
392
1%
2
1
DL4001
1
1
2
TP88
+35V
2
1
WBC
1
16
RELAY DPDT (MDX24–02)
2
LED20
NOB_SPARE
9
D1 5
1
8
2
7
3
6
4
5
CON\2X4\MILLER
GREEN
SMT
K6
6
RELAY_COM
RC91
NCA_READY
4
8
NOA_READY
11
NCB_READY
9
NOB_READY
RELAY_COM
+24RD
RD_GN D
13
TP98
D1 4
+35V
2
R5 0
392
1%
1
1
1
16
2
DL4001
2
LED21
GREEN
SMT
1
TP99
RELAY DPDT (MDX24–02)
NCA_SPARE
NOA_SPARE
NCB_SPARE
COMM_SPARE
NOA_READY
NOB_SPARE
NCA_READY
COM_READY
NOB_READY
NCB_READY
K2
RELAY_COM
6
NCA_STUCK
8
NOA_STUCK
1
8
2
9
3
10
4
11
5
12
6
13
7
14
CON\2X7\MILLE R
4
11
NCB_STUCK
9
NOB_STUCK
13
U2 1
TOUCH_SENSOR
SPARE
WLDR_RDY
STK_ERR
FLOW_ERR
ARC_DET
1
2
3
4
5
6
7
8
I1
I2
I3
I4
I5
I6
I7
GND
O1
O2
O3
O4
O5
O6
O7
V+
16
15
14
13
12
11
10
9
+35V
2
R5 3
392
1
1
2
D1 8
DL4001
2
LED17
GREEN
SMT
1
1%
TP104
1
16
RELAY DPDT (MDX24–02)
TP105
K3
ULN2003
NCA_FLOW
6
RELAY_COM
4
GND
NOA_FLOW
8
11
CON\3X5\MILLE
NOB_FLOW
9
2
R5 6
392
1%
1
2
1
16
D1 7
DL4001
6
1
11
7
2
12
8
3
13
9
4
14
10
5
15
NCB_FLOW
13
+35V
RC92
NCA_STUCK
NOA_STUCK
COMM_STUCK
NOB_STUCK
COMM_FLOW
NCB_STUCK
NCB_FLOW
NCA_FLOW
NOB_FLOW
COMM_ARC
NCB_ARC
NOA_FLOW
NCA_ARC
NOA_ARC
NOB_ARC
RELAY DPDT (MDX24–02)
1
1
TP109
2
LED18
GREEN
SMT
K4
TP108
RELAY_COM
6
NCA_ARC
8
NOA_ARC
4
11
NCB_ARC
13
9
+35V
TP114
2
R5 9
392
1%
TP115
1
2
1
16
D1 6
DL4001
NOB_ARC
Pensar 86147 (Part 3 of 3)
RELAY DPDT (MDX24–02)
1
1
2
LED19
GREEN
SMT
OM-203 860 Page 51
R
174 578-B
Figure 5-12. Circuit Diagram For Touch Sensor Board PC18
OM-203 860 Page 52
191 531
Figure 5-13. Circuit Diagram For Power Distribution Board PC20
OM-203 860 Page 53
SECTION 6 – PARTS LIST
13 14
27
25
40
35
37
36
33
38
32 (Fig.6–3)
34
23
26
31 (Fig.6–2)
1
30
3
2
4
39
29
28
5
24
6
7
8
9
4
10 11
12
15
16 17 18
3
20
21
19 (Fig.6–4)
available unless listed.
23
. Hardware is common and not
802 994-B
Figure 6-1. Main Assembly
OM-203 860 Page 54
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-1 Main Assembly
. . . 1 . . . . . . . . . . . . +179 432
. . . 2 . . . . . . . . . . . . . 179 431
. . . 3 . . . . . . . . . . . . . 164 699
. . . 4 . . . . . . . . . . . . . 162 816
. . . 5 . . . . . . . . . . . . . 162 820
. . . 6 . . . . . . . . . . . . . 162 830
. . . 7 . . . . . . . . . . . . . 177 279
. . . 8 . . . . . . . . . . . . . 604 536
. . . 9 . . . . . Z1 . . . . 166 364
. . . 10 . . . . HD1 . . . . 168 829
. . . 11 . . . . CR6 . . . . 160 966
. . . 12 . . . . . . . . . . . . . 173 605
. . . 13 . . . C21-23 . . 163 906
. . . 14 . . . . . T2 . . . . 159 042
. . . 14 . . . . . T2 . . . . 159 041
. . . 14 . . . . . T2 . . . . 159 043
. . . 15 . . . . TE1 . . . . 159 244
. . . 16 . . . . . . . . . . . . . 601 835
. . . 17 . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . . . . 601 835
. . . . . . . . . . . . . . . . . . . 038 618
. . . 18 . . . . . . . . . . . . . 159 034
. . . 19 . . . . . . . . . . . . . . Fig 6-5
. . . 20 . . . . . F1 . . . *156 065
. . . 21 . . . . . W . . . . . 160 793
. . . 23 . . . . . . . . . . . . . 134 464
. . . 24 . . . . . . . . . . . . . 163 359
. . . 25 . . . . . C1 . . . . 182 661
. . . . . . . . . . . . . . . . . . . 163 535
. . . . . . . . . . . R6 . . . . 140 002
. . . . . . . . . . . . . . . . . . . 162 817
. . . 26 . . . . . . . . . . . . . 182 660
. . . 27 . . . . . T1 . . . . 189 835
. . . 28 . . . . . . . . . . . . . 166 442
. . . 29 . . . . . . . . . . . . . 166 441
. . . 27 . . . . . T1 . . . . 189 836
. . . 28 . . . . . . . . . . . . . 172 309
. . . 29 . . . . . . . . . . . . . 172 308
. . . 27 . . . . . T1 . . . . 189 837
. . . 28 . . . . . . . . . . . . . 172 427
. . . 29 . . . . . . . . . . . . . 172 426
. . . . . . . . . TP1,2 . . . 175 405
. . . . . . . . . TP4,5 . . . 168 891
. . . . . . . . . PLG13 . . 189 873
. . . . . . . . . RC13 . . . 189 874
. . . . . . . . . PLG6 . . . 168 847
. . . . . . . . . . RC6 . . . . 168 845
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACTOR, def prp 25A 2P 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, 50 and 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . . . . . . . . . . . .
. . TRANSFORMER, control 50VA 24V 200/230/460 (60Hz) . . . . . . . . . . . . . .
. . TRANSFORMER, control 50A 24V (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACTOR, def prp 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR, elctlt 16000uf 60VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RESISTOR, WW fxd 10W 500 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . . . . . .
. . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . . . . . .
. . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, pwr main 380/400/440 (consisting of) . . . . . . . . . . . . . . .
. . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
2
4
2
1
1
2
1
1
1
1
3
1
1
1
1
24
24
24
24
8
1
1
1
1
2
1
1
6
1
2
4
1
2
1
1
2
1
1
2
1
2
2
1
1
1
1
OM-203 860 Page 55
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-1 Main Assembly (Continued)
. . . 30 . . . . . . . . . . . . . 161 294
. . . 31 . . . . . . . . . . . . . . Fig 6-2
. . . 32 . . . . SR1 . . . . 192 672
. . . . . . . . . PLG14 . . 115 094
. . . . . . . . . PLG7 . . . 152 249
. . . . . . . . . . RC7 . . . . 168 846
. . . . . . . . . . . . . . . . . . . 010 467
. . . . . . . . . . . R7 . . . ♦114 808
. . . 33 . . . . . . . . . . . . . 204 069
. . . 34 . . . PC18 . . . 174 573
. . . 35 . . . PC12 . . . 191 841
. . . 36 . . . PC11 . . . 210 361
. . . 37 . . . . PC1 . . . . 208 197
. . . 38 . . . . CR3 . . . . 052 964
. . . 39 . . . . T11 . . . . 204 979
. . . 40 . . . . CR5 . . . . 006 393
. . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, SCR main (Fig 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 375W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ELECTRONICS BOX (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, touch sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, weld interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, processor w/prom . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, control 200VA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
♦Part of Option 043 286 Additional Resistor
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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-203 860 Page 56
7
8
available unless listed.
21 20
19
23
27
25
24
26
28
29
30
22
31
32
18
1
17
16
15
2
14
3
13
4
12
11
6 7
10
6 7
. Hardware is common and not
802 997-A
Figure 6-2. Panel, Front w/Components
OM-203 860 Page 57
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-2 Panel, Front w/Components (Fig 6-1 Item 31)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
. . . . . . . . . . . . . 203 630
. . . CB1,2 . . . 093 995
. . . . RC9 . . . . 604 176
. . . . . . . . . . . . . . 204143
. . . . POS . . . 181 245
. . . C2,4,5 . . . 128 750
. . . . . . . . . . . . . 161 303
. . . . NEG . . . 181 246
. . . . . . . . . . . . . 162 891
. . . . . . . . . . . . +172 587
. . . . . . . . . . . . . 160 935
. . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . 204 067
. . . PC13 . . . 209 249
. . . PC20 . . . 191 533
. . . PC22 . . . 200 073
. . . PC17 . . . 177 290
. . . PC15 . . . 182 998
. . . . . . . . . . . . . 091 772
. . . . . . . . . . . . . 203 628
. . . . . . . . . . . . . 144 842
. . . RC70 . . . 201 058
. . . . . S2 . . . . 159 039
. . . RC21 . . . 200 082
. . . CB11 . . . 011 991
. . . PC19 . . . 134 560
. . . . RC8 . . . . 200 589
. . . PC21 . . . 200 077
. . . RC25 . . . 200 591
. . . PC14 . . . 203 665
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, stud output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, 115V motor board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPLAY, LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, switch board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, NO 6-32 x .625 LG .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, rect 72 pin assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, circ 97/met 4 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, man reset 1P 1.5A 250V . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, circ 97/met 10 skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, robot interface filter hf . . . . . . . . . . . . . . . . . . . . . . . .
CONN, circ 97/met 11 skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, customer interface . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
2
3
3
1
1
1
3
1
1
1
1
1
1
1
4
1
3
1
1
1
1
1
1
1
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-203 860 Page 58
. Hardware is common and not
available unless listed.
3
2
1
4
5
6
Figure 6-3. Rectifier, SCR Main SR1
Item
No.
Dia.
Mkgs.
SR1
Part
No.
Description
Figure 6-3 Rectifier, SCR Main (Fig 6-1 Item 32)
802 351
Quantity
192 672
. . . 1 . . . . C7-12 . . . . 048 420 . . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 2 . . . . . . . . . . . . . . . 191 989 . . BAR, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 188 691 . . CLAMP, thyristor rectifier 5.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 4 . . . . . . . . . . . . . . . 188 839 . . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 5 . . . SCR1-6 . . . 161 668 . . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 6 . . . . . . . . . . . . . . . 166 667 . . CLAMP, spring thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG1 . . . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . TP3 . . . . . 192 673 . . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . TP6 . . . . . 192 674 . . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-203 860 Page 59
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-4 Panel, Rear w/Components (Fig 6-1 Item 19)
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
. . . . . . . . . . . . . . . 173 283
. . . . . . . . . . . . . . . 180 165
. . . . . . . . . . . . . . . 162 807
. . . . . . . . . . . . . . . 168 343
. . . . . . . . . . . . . . +162 818
. . . . . . . . . . . . . . . 168 384
. . . . . . . . . . . . . . . 602 177
. . . . . . . . . . . . . . . 124 274
. . . . . R3 . . . . . . 114 808
. . . . . FM . . . . . 116 190
. . . . . . . . . . . . . . . 194 745
. . . . . . . . . . . . . . . 010 467
..
..
..
..
..
..
..
..
..
..
..
..
CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE, fan 14 in 3wg 28deg .375 bore CCW . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HINGE, door primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR, access primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, set .250-20 x .250knrlpt sch stl . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 375W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . .
BLOCKING DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
. Hardware is common and not
1
1
1
2
1
1
2
1
1
1
1
1
4
available unless listed.
5
6
2
1
(Fig.6-5)11
7
12
8
10
9
Ref. 802 798 / 800 707-B
Figure 6-4. Panel, Rear w/Components
+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-203 860 Page 60
802 686-A
Figure 6-5. Blocking Diode
Item
No.
Part
No.
Description
Quantity
Figure 6-5. Blocking Diode (Fig 6-4 Item 11)
... 1 ...............
... 2 ...............
... 3 ...............
... 4 ...............
... 5 ...............
... 6 ...............
... 7 ...............
.....................
.....................
200 355
191 248
086 353
048 775
166 667
201 059
048 420
168 894
192 731
..
..
..
..
..
..
..
..
..
Bracket, Mtg Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Sink, rectifier snowflake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode, Rect 800A 300V R7S Hockey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, Tab Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, spring thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, thyristor rectifier 4.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, cer disc .01 uf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat, Nc Open 125F Close 105F No Flangew/leads . . . . . . . . . . .
Thermostat, Nc Open 203F Close 173F No Flangew/leads . . . . . . . . . . .
1
2
1
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-203 860 Page 61
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
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.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
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.
miller_warr 6/02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
8/02