Escolar Documentos
Profissional Documentos
Cultura Documentos
2015−03
Processes
Multiprocess Welding
Description
Dimension
CE and non-CE
File: Multi-Process
Mil_Thank 2009−09
TABLE OF CONTENTS
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number
Dimension 812 907361
Council Directives:
• 2006/95/EC Low Voltage
• 2004/108/EC Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment
Standards:
• IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-10:2007 Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
_____________________________________ ___________________________________________
David A. Werba Date of Declaration
241431F
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
OM-278 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au D Surveiller tout déclenchement d’incendie et tenir un extincteur à
niveau de l’arc pour l’évacuation des fumées et des gaz de proximité.
soudage. Pour déterminer la bonne ventilation, il est recommandé D Le soudage effectué sur un plafond, plancher, paroi ou séparation
de procéder à un prélèvement pour la composition et la quantité peut déclencher un incendie de l’autre côté.
de fumées et de gaz auxquels est exposé le personnel.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
approuvé. préparés correctement conformément à AWS F4.1 et AWS A6.0
D Lire et comprendre les fiches de données de sécurité et les instruc- (voir les Normes de Sécurité).
tions du fabricant concernant les adhésifs, les revêtements, les D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
nettoyants, les consommables, les produits de refroidissement, les peurs inflammables (vapeur d’essence, par exemple).
dégraisseurs, les flux et les métaux.
D Brancher le câble de masse sur la pièce le plus près possible de la
D Travailler dans un espace fermé seulement s’il est bien ventilé ou zone de soudage pour éviter le transport du courant sur une
en portant un respirateur à alimentation d’air. Demander toujours à longue distance par des chemins inconnus éventuels en provo-
un surveillant dûment formé de se tenir à proximité. Des fumées et quant des risques d’électrocution, d’étincelles et d’incendie.
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels. D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
S’assurer que l’air de respiration ne présente aucun danger. lées.
D Ne pas souder dans des endroits situés à proximité d’opérations D En cas de non utilisation, enlever la baguette d’électrode du porte-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et électrode ou couper le fil à la pointe de contact.
les rayons de l’arc peuvent réagir en présence de vapeurs et for- D Porter un équipement de protection pour le corps fait d’un matériau
mer des gaz hautement toxiques et irritants. résistant et ignifuge (cuir, coton robuste, laine). La protection du
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier corps comporte des vêtements sans huile comme par ex. des
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- gants de cuir, une chemise solide, des pantalons sans revers, des
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit chaussures hautes et une casquette.
bien ventilé, et en portant un respirateur à alimentation d’air. Les D Avant de souder, retirer toute substance combustible de vos po-
revêtements et tous les métaux renfermant ces éléments peuvent ches telles qu’un allumeur au butane ou des allumettes.
dégager des fumées toxiques en cas de soudage.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
LES RAYONS DE L’ARC peuvent trace d’étincelles incandescentes ni de flammes.
provoquer des brûlures dans les D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
yeux et sur la peau. Ne pas augmenter leur puissance; ne pas les ponter.
Le rayonnement de l’arc du procédé de soudage D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
génère des rayons visibles et invisibles intenses trace d’étincelles incandescentes ni de flammes.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
dans les yeux et sur la peau. Des étincelles sont projetées pendant le Ne pas augmenter leur puissance; ne pas les ponter.
soudage.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
D Porter un casque de soudage approuvé muni de verres filtrants NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
approprié pour protéger visage et yeux pour protéger votre visage extincteur à proximité.
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 D Lire et comprendre les fiches de données de sécurité et les instruc-
et Z87.1 énuméré dans les normes de sécurité).
tions du fabricant concernant les adhésifs, les revêtements, les
D Porter des lunettes de sécurité avec écrans latéraux même sous nettoyants, les consommables, les produits de refroidissement,
votre casque. les dégraisseurs, les flux et les métaux.
OM-278 Page 6
DES PIECES DE METAL ou DES LES BOUTEILLES peuvent exploser
SALETES peuvent provoquer des si elles sont endommagées.
blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser. Du fait que les
pièce à la brosse en fil de fer, et le meulage gé- bouteilles de gaz font normalement partie du
nèrent des étincelles et des particules procédé de soudage, les manipuler avec
métalliques volantes. Pendant la période de précaution.
refroidissement des soudures, elles risquent D Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
de projeter du laitier. ve, des chocs mécaniques, des dommages physiques, du lai-
D Porter des lunettes de sécurité avec écrans latéraux ou un écran tier, des flammes ouvertes, des étincelles et des arcs.
facial. D Placer les bouteilles debout en les fixant dans un support sta-
tionnaire ou dans un porte-bouteilles pour les empêcher de tom-
ber ou de se renverser.
LES ACCUMULATIONS DE GAZ D Tenir les bouteilles éloignées des circuits de soudage ou autres
risquent de provoquer des blessures circuits électriques.
ou même la mort. D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Fermer l’alimentation du gaz comprimé en cas D Une électrode de soudage ne doit jamais entrer en contact avec
de non utilisation. une bouteille.
D Veiller toujours à bien aérer les espaces confi- D Ne jamais souder une bouteille pressurisée − risque d’explosion.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application
Les CHAMPS ÉLECTROMAGNÉTIQUES spécifique; les maintenir ainsi que les éléments associés en bon
état.
(CEM) peuvent affecter les implants mé-
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
dicaux. de la bouteille. Ne pas se tenir devant ou derrière le régulateur
lors de l’ouverture de la vanne.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à D Le couvercle du détendeur doit toujours être en place, sauf lors-
distance. que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
D Les porteurs d’implants médicaux doivent consulter leur
D Utiliser les équipements corrects, les bonnes procédures et suf-
médecin et le fabricant du dispositif avant de s’approcher de la
fisamment de personnes pour soulever et déplacer les bouteil-
zone où se déroule du soudage à l’arc, du soudage par points, du les.
gougeage, de la découpe plasma ou une opération de chauffage
par induction. D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sé-
LE BRUIT peut endommager l’ouïe. curité.
OM-278 Page 8
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)
OM-278 Page 9
OM-278 Page 10
. A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE
products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Safe5 2012−05
Safe6 2012−05
Safe8 2012−05
Safe10 2012−05
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Safe16 2012−05
OM-278 Page 11
. A complete Parts List is available at www.MillerWelds.com
Safe20 2012−05
Safe30 2012−05
? V
? A Consult rating label for input power requirements.
Safe34 2012−05
Read Owner’s Manual and inside labels for connection points and procedures.
ÍÍ Safe67 2012−06
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Safe40 2012−05
?V
Move jumper links as shown on inside label to match input voltage at
job site. Include extra length in grounding conductor and connect
ÍÍ
grounding conductor first. Connect line input conductors as shown on
inside label. Double-check all connections, jumper link positions, and
Safe69 2012−06
OM-278 Page 12
. A complete Parts List is available at www.MillerWelds.com
A Amperage
Negative Weld
Output Terminal S1 Product of Voltage
and Current (KVA)
Positive High
V Voltage Inductance Weld
Output Terminal
Gas Tungsten Arc
Welding (GTAW)
On Percent Remote
Direct Current
Three Phase Arc Force (DIG)
(DC)
Suitable For
S
Welding In An
Environment With U0 Rated No−Load
Voltage (OCV)
Do Not Switch
While Welding
Increased Risk Of
Electric Shock
Wire Feed
U1 Primary Voltage Temperature
Output
U2 Conventional
Load Voltage
Amperage/Voltage
Control−Panel
Input
Three-Phase
Circuit Breaker I2 Rated Welding
Current
Transformer
Rectifier
Supplementary
Protector
X Duty Cycle IP Degree Of
Protection
OM-278 Page 13
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-2. Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-13, 5-14 and 5-15 for information
on connecting input power.
! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances.
IEC/TS 61000−3−4 can be used to guide parties concerned by the installation of arc welding equipment with an input current greater than 75
A in a low-voltage network.
ce-emc 5 2014-07
OM-278 Page 14
. A complete Parts List is available at www.MillerWelds.com
Continuous Welding
Overheating
0 A/V
15
OR
Minutes Reduce Duty Cycle
168 918
80 70
SMAW GMAW
GTAW MAX
70 FCAW
60
60
50
50
DC Volts
DC Volts
40
40 MED
SMAW 30
30 ARC FORCE
20 SMAW 20
ARC FORCE
10 10
MIN
MIN MAX MIN MAX
0 0
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000
DC Amperes DC Amperes
OM-278 Page 15
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Selecting A Location
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
3 Line Disconnect Device
Locate unit near correct input
power supply.
1
! Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
OR
18 in.
(460 mm)
18 in.
(460 mm)
OM-278 Page 16
. A complete Parts List is available at www.MillerWelds.com
Dimensions
A
A 30 in. (762 mm) Including lift eye
F
G E 1-1/4 in. (32 mm)
H
4 Holes
Weight
Notes
OM-278 Page 17
. A complete Parts List is available at www.MillerWelds.com
5-3. Tipping
! Be careful when placing or
moving unit over uneven
surfaces.
OM-278 Page 18
. A complete Parts List is available at www.MillerWelds.com
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
700 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120) 4x4/0 (4x120)
800 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x4/0 (3x120) 3x4/0 (3x120) 4x4/0 (4x120) 4x4/0 (4x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02
1 2
OM-278 Page 19
. A complete Parts List is available at www.MillerWelds.com
2
6
3
1
Tools Needed: 5
3/4 in. (19 mm)
803 778-B
! Turn off power before connecting to cable terminal and copper bar. Make 5 Weld Cable Terminal
weld output terminals. sure that the surfaces of the weld cable
terminal and copper bar are clean. 6 Copper Bar
! Failure to properly connect weld
cables may cause excessive heat 1 Correct Weld Cable Connection Remove supplied nut from weld output ter-
and start a fire, or damage your ma- 2 Incorrect weld Cable Connection minal. Slide weld cable terminal onto weld
chine. output terminal and secure with nut so that
3 Weld Output Terminal weld cable terminal is tight against copper
. Do not place anything between weld 4 Supplied Weld Output Terminal Nut bar.
connecting weld output cables 3−2010
Gas Flowmeter/
Regulator
HIGH LOW
INDUCTANCE INDUCTANCE
or
. For better performance for most GMAW (DCEP and DCEN)
applications, it is recommended that weld output connec-
tions be made to the Low Inductance weld output terminal. Rear Of
Wire Feeder
OM-278 Page 20
. A complete Parts List is available at www.MillerWelds.com
GMAW / FCAW
Gas Flowmeter/
Regulator
HIGH LOW
INDUCTANCE INDUCTANCE
(Gasless FCAW)
+ + −
or
FCAW (Gasless)
LOW
INDUCTANCE
(Gasless FCAW)
+ + −
Rear Of
Wire Feeder
OM-278 Page 21
. A complete Parts List is available at www.MillerWelds.com
HIGH
INDUCTANCE
+ + −
OM-278 Page 22
. A complete Parts List is available at www.MillerWelds.com
A J
K I
B
C L N H
D M G
E F
OR OR
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
60 Hz Models 50 Hz Models
Input Voltage (V) 230 460 575 380 400 440 520
Input Amperes (A) At Rated Output 126 63 50.4 77 73 66 54
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 150 70 60 90 90 80 60
Normal Operating Fuses 3 200 90 80 125 110 100 80
Min Input Conductor Size In AWG 4 1 6 6 4 4 4 6
Max Recommended Input Conductor Length In Feet (Me- 208 328 513 335 371 449 419
ters) (64) (100) (156) (102) (113) (137) (128)
Min Grounding Conductor Size In AWG 4 6 8 8 6 6 8 8
OM-278 Page 23
. A complete Parts List is available at www.MillerWelds.com
1
(FACTORY OPTION) Ref. S-174 975-B
177 159-A
Do not overtighten
jumper link nuts.
Tools Needed:
3/8 in.
3/8 in.
OM-278 Page 24
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-278 Page 25
. A complete Parts List is available at www.MillerWelds.com
11
10
6 3
Input Contactor
L1
7 L2
L3
4
=
GND/PE Earth Ground
4
3
Tools Needed:
5/32 in. 3/8, 1/2 in.
3/8 in.
input3 2015−01 − Ref. 803 766-C / 800 103-D / Ref. 801 116-A
OM-278 Page 26
. A complete Parts List is available at www.MillerWelds.com
! Installation must meet all National capacity and correct hole size. Connect input conductors L1 (U), L2 (V) and
and Local Codes − have only qualified L3 (W) to welding power source line
persons make this installation. Welding Power Source Input Power Con- terminals.
nections
Close and secure access door on welding
! Disconnect and lockout/tagout input 2 Strain Relief (Customer Supplied) power source.
power before connecting input con-
ductors from unit. Follow established Install strain relief of proper size for unit and Disconnect Device Input Power Connec-
procedures regarding the installation conductors. Route conductors (cord) tions
and removal of lockout/tagout through strain relief. Tighten strain relief. 8 Disconnect Device (switch shown in
devices. OFF position)
3 Welding Power Source Grounding
! Make input power connections to the Terminal 9 Disconnect Device (Supply) Grounding
Terminal
welding power source first. 4 Green Or Green/Yellow Grounding 10 Disconnect Device Line Terminals
Conductor
! Always connect green or green/yel- Connect green or green/yellow grounding
low conductor to supply grounding 5 Reed Switch (Ground Current Sensor) conductor to disconnect device grounding
terminal first, and never to a line ter- (Optional) terminal first.
minal.
Connect green or green/yellow grounding Connect input conductors L1 (U), L2 (V) And
See rating label on unit and check input volt- conductor to welding power source ground- L3 (W) to disconnect device line terminals.
age available at site. ing terminal first. If unit is equipped with op- 11 Over-Current Protection
tional ground current sensor, route grounding
1 Input Power Conductors (Customer conductor through reed switch two times and Select type and size of over-current protec-
Supplied Cord) connect to grounding terminal. tion using Section 5-13 (fused disconnect
switch shown).
Select size and length of conductors using 6 Welding Power Source Line Terminals
Section 5-13. Conductors must comply with Close and secure door on line disconnect de-
national, state, and local electrical codes. If 7 Input Conductors L1 (U), L2 (V) And L3 vice. Follow established lockout/tagout pro-
applicable, use lugs of proper amperage (W) cedures to put unit in service.
input3 2015−01
Notes
OM-278 Page 27
. A complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATION
6-1. Controls (Non CE Models)
1 2 3 4
8 7 6 5
184 939-C
1 Arc Force (Dig) Control GTAW, use the Positive (+) High Induc- display actual output voltage and amperage
tance weld output terminal (see Section with contactor on.
Control increases SMAW short-circuit
5-6).
amperage which allows the operator to use 5 Power Switch With Indicator Light
a very short arc length without sticking the 3 Amperage/Voltage Adjustment Control 6 High Temperature Shutdown Light
electrode. When Process Selector switch is in the 7 Remote Amperage/Voltage Control
Set control at 0 for normal welding amperage SMAW/GTAW position, turn control clock- Switch
and GTAW applications. Turn clockwise to wise to increase amperage. Read amperage
increase short-circuit amperage. from outer scale of control. When Process For front panel control, place switch in Panel
Selector switch is in the GMAW position, turn position. For remote control, place switch in
2 Process Selector Switch control clockwise to increase voltage. Volt- Remote position, and connect remote de-
• GMAW Mode: For use with flux Cored meter value changes as control knob is vice (see Section 5-12).
(FCAW) or submerged arc (SAW) applica- turned. Control can be adjusted while 8 Output Switch (Contactor)
tions. welding.
For front panel control of output, place switch
• SMAW (Hot Start On) Mode: Hot Start is 4 Digital Meters in Panel position. For remote control of out-
energized for Stick (SMAW). When Hot With Process Selector switch in the SMAW/ put, place switch in Remote position, and
Start is energized, higher short circuit am- GTAW position, digital meters will read 0 connect remote device (see Section 5-12).
perage aids in arc starting. Use the Posi- (zero) with contactor off. Digital meters will
tive (+) High Inductance weld output termi- display actual output voltage and amperage ! Weld output studs are energized only
nal (see Section 5-6). with contactor on. when Output switch is in On position,
or while welding.
• SMAW (Hot Start Off) Mode: For use with With Process Selector switch in the GMAW
TIG (GTAW), scratch start only, or sub- position, voltmeter displays preset voltage ! Turn Off power before connecting re-
merged arc (SAW) applications. For with contactor off. Voltmeter and ammeter mote device.
OM-278 Page 28
. A complete Parts List is available at www.MillerWelds.com
1 2 3 4
8 7 6 5
184 936-D
1 Arc Force (Dig) Control GTAW, use the Positive (+) High Induc- display actual output voltage and amperage
Control increases SMAW short-circuit tance weld output terminal (see Section with contactor on.
amperage which allows the operator to use 5-6). 5 Power Switch With Indicator Light
a very short arc length without sticking the 3 Amperage/Voltage Adjustment Control 6 High Temperature Shutdown Light
electrode. When Process Selector switch is in the 7 Remote Amperage/Voltage Control
Set control at 0 for normal welding amperage SMAW/GTAW position, turn control clock- Switch
and GTAW applications. Turn clockwise to wise to increase amperage. Read amperage
from outer scale of control. When Process For front panel control, place switch in Panel
increase short-circuit amperage.
Selector switch is in the GMAW position, turn position. For remote control, place switch in
2 Process Selector Switch control clockwise to increase voltage. Volt- Remote position, and connect remote de-
• GMAW Mode: For use with flux Cored meter value changes as control knob is vice (see Section 5-12).
(FCAW) or submerged arc (SAW) applica- turned. Control can be adjusted while 8 Output Switch (Contactor)
tions. welding.
For front panel control of output, place switch
• SMAW (Hot Start On) Mode: Hot Start is 4 Digital Meters in Panel position. For remote control of out-
energized for Stick (SMAW). When Hot With Process Selector switch in the SMAW/ put, place switch in Remote position, and
Start is energized, higher short circuit am- GTAW position, digital meters will read 0 connect remote device (see Section 5-12).
perage aids in arc starting. Use the Posi- (zero) with contactor off. Digital meters will
tive (+) High Inductance weld output termi- display actual output voltage and amperage ! Weld output studs are energized only
nal (see Section 5-6). with contactor on. when Output switch is in On position,
or while welding.
• SMAW (Hot Start Off) Mode: For use with With Process Selector switch in the GMAW
TIG (GTAW), scratch start only, or sub- position, voltmeter displays preset voltage ! Turn Off power before connecting re-
merged arc (SAW) applications. For with contactor off. Voltmeter and ammeter mote device.
OM-278 Page 29
. A complete Parts List is available at www.MillerWelds.com
3 Months
6 Months
7-2. Fuse F1
! Disconnect and lockout/tag-
out input power before
checking or changing fuse.
1 Fuse F1 (See Section 8 For
Rating)
Fuse F1 protects control transform-
1 er from overload. If F1 opens, weld
output and fan motor stops. Re-
place F1.
Close and secure access door.
Tools Needed:
3/8 in. Ref. 800 101-C
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-278 Page 30
. A complete Parts List is available at www.MillerWelds.com
7-4. Troubleshooting
Trouble Remedy
No weld output; unit completely Place line disconnect device in On position (see Section 5-15).
inoperative; pilot light PL1 off.
Check for open line fuse(s), and replace if open (see Section 5-15).
Check for proper input power connections (see Section 5-15).
Check for proper jumper link position (see Section 5-14).
Check fuse F1, and replace if necessary (see Section 7-2).
No weld output; power switch pilot light Unit overheated. Allow unit to cool with fan On (see Section 4-4).
on.
If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote
control (see Sections 5-11 and 5-12). If remote is not being used, place switch in On position (see
Section 6-1).
Check, repair, or replace remote control.
No weld output; power switch pilot light Check for proper input power connections (see Section 5-15).
on; fan off.
Check for open line fuse(s), and replace if open, or reset circuit breaker (see Section 5-15).
Turn power switch off then back on. If no output condition remains, have Factory Authorized Service
agent check SCR’s.
Limited weld output and low Check position of Remote Amperage/Voltage Control switch (see Section 6-1).
open-circuit voltage.
Check for open line fuse(s), and replace if open (see Section 5-15).
Check for proper input power connections (see Section 5-15).
Check for proper jumper link position (see Section 5-14).
Clean and tighten all weld output connections.
Unit provides only maximum or Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
minimum weld output.
Check position of Remote Amperage/Voltage Control switch (see Section 6-1).
Not able to obtain minimum output in Use high inductance weld output terminal when in CC mode to obtain minimum output (see Section
CC mode. 5-6).
Erratic or improper weld output. Use proper size and type of weld cable (see Section 5-5).
Clean and tighten all weld connections.
Check wire feeder installation according to Owner’s Manual.
Check position of Process selector switch (see Section 6-1).
Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
No 115 volts AC output at duplex re- Reset supplementary protector CB1 (see Section 5-4).
ceptacle.
No 24 volts AC output at Remote 14 Reset supplementary protector CB2 (see Section 5-4).
receptacle.
Fan not operating. Note: fan only runs Check for and remove anything blocking fan movement.
when cooling is necessary.
Have Factory Authorized Service Agent check fan motor.
Wandering arc; poor control of arc Reduce gas flow rate.
direction.
Select proper size tungsten.
Properly prepare tungsten.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary. See torch Owner’s Manual.
Digital meter not working properly. Have Factory Authorized Service Agent check control board PC1 and connections, and replace if
necessary.
OM-278 Page 31
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-278 Page 32
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-278 Page 33
SECTION 9 − ELECTRICAL DIAGRAM
OM-278 Page 34
267 479-A
OM-278 Page 35
Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
for your local EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the * Roughneck Guns
reliable response you troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure.
* Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. 1. Consumable components; such as contact tips,
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support station table tops and welding curtains, or parts that
to the original end-user purchaser, and not to exceed twelve months
Need fast answers to the fail due to normal wear. (Exception: brushes and
after the equipment is shipped to a North American distributor or
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is covered by the manufacturer’s warranty, if any.
* Original Main Power Rectifiers Only to Include SCRs,
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. Miller, or equipment that has been improperly installed,
2. 3 Years — Parts and Labor
improperly operated or misused based upon industry
* Auto-Darkening Helmet Lenses (Except Classic standards, or equipment which has not had reasonable
Series) (No Labor) and necessary maintenance, or equipment which has
* Engine Driven Welder/Generators been used for operation outside of the specifications for
(NOTE: Engines are Warranted Separately by the the equipment.
Engine Manufacturer.)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Inverter Power Sources (Unless Otherwise Stated) USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Plasma Arc Cutting Power Sources TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
3. 2 Years — Parts and Labor
cases, (3) the reasonable cost of repair or replacement at an
* Auto-Darkening Helmet Lenses − Classic Series Only authorized Miller service station; or (4) payment of or credit for the
(No Labor) purchase price (less reasonable depreciation based upon actual
* Fume Extractors − Capture 5, Filtair 400 and Industrial use) upon return of the goods at customer’s risk and expense.
Collector Series Miller’s option of repair or replacement will be F.O.B., Factory at
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
* CoolBelt and CoolBand Blower Unit (No Labor)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Desiccant Air Dryer System
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* External Monitoring Equipment and Sensors REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Field Options DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
(NOTE: Field options are covered for the remaining CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
warranty period of the product they are installed in, or WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
for a minimum of one year — whichever is greater.) LEGAL THEORY.
* RFCS Foot Controls (Except RFCS-RJ45) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* Fume Extractors − Filtair 130, MWX and SWX Series IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
* LiveArc Welding Performance Management System PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Load Banks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns)
Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
* Water Coolant Systems additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2015-01
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2015 Miller Electric Mfg. Co. 2015−01