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— answers from the official manualAnswers from the official manual.
Common questions
Common Questions
19 totalWhat are the rated output specifications for the Millermatic 350P?
The Millermatic 350P is rated at 300 A at 32 VDC at 60% duty cycle, and 350 A at 32 VDC at 40% duty cycle. The maximum open circuit voltage is 90V, and the unit operates at 60 Hz. Wire feed speed ranges from 50 to 700 IPM (1.3–17.8 m/min). (Page 9)
How do I thread welding wire for the Roughneck gun?
Lay the gun cable out straight, then open the pressure assembly and cut off the end of the wire. Push the wire through the guides into the gun, then close and tighten the pressure assembly. Remove the gun nozzle and contact tip, turn the unit on, press the gun trigger until wire comes out, then reinstall the contact tip and nozzle. Finally, feed wire to check drive roll pressure and tighten the knob enough to prevent slipping. (Page 21)
What shielding gas flow rate is recommended for the Millermatic 350P?
A typical flow rate of 20 CFH (cubic feet per hour) is recommended. You should also check the wire manufacturer's recommended flow rate, as it may vary. Note that you should not use an Argon/Mixed gas regulator/flowmeter with CO2 shielding gas — see the Parts List for an optional CO2 gas regulator/flowmeter. (Page 16)
How do I set the correct gun polarity for different wire types on the Millermatic 350P?
The unit ships configured as Electrode Positive (DCEP), which is correct for solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW). For gasless flux core wires (FCAW), you must reverse the lead connections at the terminals to set Electrode Negative (DCEN), making the drive assembly negative. Always read and follow the wire manufacturer's recommended polarity. (Page 15)
What voltages and wire feed speeds are recommended for MIG welding 1/4-inch steel with .035 wire and 75% Argon/25% CO2 gas?
For 1/4-inch (6.4 mm) steel using .035 wire and 75% Argon/25% CO2 gas, the recommended setting is 23.0 volts at 325 IPM wire feed speed. All chart parameters reference settings for horizontal T fillet welds, so settings may need to be modified for other joint types or welding positions. An inductance setting of 20–40 is suggested for this wire and gas combination. (Page 26)
What is the Tip Saver feature on the Millermatic 350P?
The Tip Saver feature automatically shuts off the welding arc after 1 second if the gun contact tip is directly shorted to the workpiece while the gun trigger is pressed. This prevents wire burnback in the contact tip. No user action is required — the protection is automatic. (Page 25)
Show 13 more questions
What minimum circuit breaker or fuse size is required for the Millermatic 350P on a 230V single-phase circuit?
What safety precautions should I follow to reduce electromagnetic field (EMF) exposure while welding?
How do I properly set up the work clamp?
What is necessary before installing a gas supply?
How do I install a spoolmatic gun?
How do I install a Roughneck gun?
How do I set the gun polarity for different wires?
How do I check if my input voltage matches the welder specifications?
What is recommended for maintaining control of voltage in Pulse MIG mode?
What safety hazards should be considered when connecting to welding output terminals?
What is the duty cycle of the Millermatic 350P and what happens if it overheats?
How do I perform a system reset on the Millermatic 350P?
What steps are necessary to connect the weld output terminals?
Full Manual
69 pages
Millermatic 350 And Millermatic 350P with Roughneck 4012 Gun Processes Description Arc Welding Power Source and Wire Feeder
Om-1327
213 814P
2006−03 MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding File: MIG (GMAW) Visit our website at www.MillerWelds.com
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard. Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. From Miller to You Mil_Thank 4/05
Table Of Contents
Section 1 − Safety Precautions - Read Before Using
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 2 − Consignes De Sécurité − Lire Avant Utilisation
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symboles utilisés 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . . 2-4. Proposition californienne 65 Avertissements 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Information EMF 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 3 − Installation
9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Duty Cycle And Overheating 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Volt-Ampere Curve 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Connecting To Weld Output Terminals 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Installing Work Clamp 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Installing Welding Gun/Cable Holder 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Installing Welding Gun 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Connecting Spoolmatic) 15A Or 30A Gun 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Connecting XR Edge, XR-A Gun, Or XR-A Python 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. Setting Gun Polarity For Wire Type 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11. Installing Gas Supply 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12. Installing Wire Spool and Adjusting Hub Tension 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13. Electrical Service Guide 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14. Selecting Input Voltage (200/230/460 Volt Models Only) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15. Selecting A Location And Connecting 3-Phase Input Power 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16. Selection A Location And Connecting 1-Phase Input Power 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17. Threading Welding Wire For Roughneck Gun 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18. Threading Welding Wire For XR Edge, XR-A Gun, Or XR-A Python 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19. Threading Welding Wire Through XR Guns 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 4 − Operation
24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. MIG Mode 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Jog Mode 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Weld Status 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. MIG Gun-On-Demand 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Pulse MIG Mode Voltage Adjustment 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Pulse MIG Gun-On-Demand 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Tip Saver 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Weld Parameters For MIG And Pulse Mode 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Recommended Crater Fill Parameters 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table Of Contents
Section 5 − Programming
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. MIG Welding Mode 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Pulse MIG Welding Mode 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Timers 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill 33 . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Setting Crater Fill 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Setting Hot Start (Aluminum Pulse Only) Parameters 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. System Reset 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 6 − Maintenance &Troubleshooting
37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Overheating 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Measuring Input Capacitor Voltage 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Changing Drive Roll and Wire Inlet Guide 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Troubleshooting 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Help Displays 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 7 − Electrical Diagram
44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 8 − Parts List
48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warranty
OM-1327 Page 1
Section 1 − Safety Precautions - Read Before Using
som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Additional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoid- able or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conduc- tor first − double-check connections. Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists in inverter-type welding power sources after removal of input power. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breath- ing air is safe. Do not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
OM-1327 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RAYS can burn eyes and skin. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant mate- rial (leather, heavy cotton, or wool) and foot protection. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. WELDING can cause fire or explosion. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. HOT PARTS can cause severe burns. Do not touch hot parts bare handed. Allow cooling period before working on gun or torch. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MAGNETIC FIELDS can affect pacemakers. Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged. Protect compressed gas cylinders from excessive heat, mechani- cal shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fit- tings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient num- ber of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
OM-1327 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. MOVING PARTS can cause injury. Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can cause injury. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. MOVING PARTS can cause injury. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before re- connecting input power.
Read Instructions.
Read Owner’s Manual before using or servic- ing unit. Use only genuine Miller/Hobart replacement parts. H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive elec- tronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. 1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
OM-1327 Page 4 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard
Aws
F4.1
from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web- site: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, CanadaM9W
1R3
(phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- ternational.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices−−phone for Region 5, Chicago, is 312−353−2220, website: www.osha.gov). 1-6. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power- frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures:
OM-1327 Page 5
Section 2 − Consignes De Sécurité − Lire Avant Utilisation
fre_som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Indique un message de sécurité particulier Signifie NOTE ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie Avertissement ! Attention ! Risques d’ÉLECTROCUTION,Organes
Mobiles
etParties
CHAUDES. Consulter les symboles et les instructions afférentes ci-dessous concernant les mesures à prendre pour supprimer les dangers. 2-2. Dangers relatifs au soudage à l’arc Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité. Seul un personnel qualifié est autorisé à installer, faire fonction- ner, entretenir et réparer cet appareil. Pendant le fonctionnement, maintenir à distance toutes les per- sonnes, notamment les enfants de l’appareil. UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. Ne pas toucher aux pièces électriques sous tension. Porter des gants isolants et des vêtements de protection secs et sans trous. S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol. Ne pas se servir de source électrique à courant électrique dans les zo- nes humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique à courant électrique s’avère né- cessaire, se servir de la fonction de télécommande si l’appareil en est équipé. D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à ge- noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul ! Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes nationales, provinciales et locales. Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort. L’équipement doit être hors tension lorsqu’il n’est pas utilisé. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le- champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel. Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. S’assurer que tous les panneaux et couvercles sont correctement en place. Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indi- quées dans la partie Entretien avant de toucher les pièces. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereuse pour la santé. LES FUMÉES ET LES GAZ peuvent être dangereux. Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va- peurs. À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Si la ventilation est médiocre, porter un respirateur anti-vapeurs approu- vé. Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un sur- veillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo- quant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. Ne pas souder dans des endroits situés à proximité d’opérations de dé- graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz haute- ment toxiques et irritants. Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal- vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxi- ques en cas de soudage.
OM-1327 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Porter un casque de soudage approuvé muni de verres filtrants ap- proprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des lunettes de sécurité avec écrans latéraux même sous vo- tre casque. Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peuvent provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, une surchauffe ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. LE SOUDAGE peut provoquer un incendie ou une explosion. Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi- gneusement avec des protections homologuées. Ne pas souder dans un endroit où des étincelles peuvent tomber sur des substances inflammables. Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Afin d’éliminer tout risque de feu, être vigilant et garder toujours un extincteur à la portée de main. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa- rés correctement conformément à AWS F4.1 (voir les normes de sécurité). Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie. Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. En cas de non-utilisation, enlever la baguette d’électrode du porte- électrode ou couper le fil à la pointe de contact. Porter des vêtements de protection exempts d’huile tels que des gants en cuir, une veste résistante, des pantalons sans revers, des bottes et un casque. Avant de souder, retirer toute substance combustible de ses poches telles qu’un allumeur au butane ou des allumettes. Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B pour travaux de soudage et prévoir un détecteur d’incendie et un ex- tincteur à proximité.
Des
Particules
Volantes
peuvent blesser les yeux. Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.Les
Accumulations
De
Gaz
risquent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non-utilisation. Veiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher des parties chaudes à mains nues. Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche. Ne pas toucher aux pièces chaudes, utiliser les outils recom- mandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. Porteurs de stimulateur cardiaque, rester à distance. Les porteurs d’un stimulateur cardiaque doi- vent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points. LE BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endomma- gée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. Protéger les bouteilles de gaz comprimé d’une chaleur excessi- ve, des chocs mécaniques, des dommages physiques, du lai- tier, des flammes ouvertes, des étincelles et des arcs. 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. Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifi- que ; les maintenir ainsi que les éléments associés en bon état. Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille. Le couvercle du détendeur doit toujours être en place, sauf lors- que la bouteille est utilisée ou qu’elle est reliée pour usage ulté- rieur. Utiliser les équipements corrects, les bonnes procédures et suf- fisamment de personnes pour soulever et déplacer les bouteil- les. 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 sécuri- té. LES BOUTEILLES peuvent exploser si elles sont endommagées.
OM-1327 Page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO-
Sion.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Ne pas installer l’appareil à proximité de produits inflammables. Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’APPAREIL peut blesser. Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.L’Emploi
Excessif
peutSur-
Chauffer L’Équipement.
Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages d’air du poste.Les Charges Électrostatiques
peuvent endommager les circuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistati- ques pour stocker, déplacer ou expédier des cartes PC. DES ORGANES MOBILES peuvent provoquer des blessures. Ne pas s’approcher des organes mobiles. Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. S’abstenir de toucher des organes mobiles tels que des ventilateurs. Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour l’entretien. Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.Lire Les Instructions.
Lire le manuel d’utilisation avant d’utiliser ou d’intervenir sur l’appareil. Utiliser uniquement des pièces de rechange Miller/Hobart.Le
Rayonnement
Haute
FRÉQUENCE (HF) risque de provoquer des interférences. Le rayonnement haute fréquence (HF) peut provoquer des interférences avec les équipe- ments de radio-navigation et de communica- tion, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’instal- lation. L’utilisateur est tenu de faire corriger rapidement par un électri- cien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. LE SOUDAGE À L’ARC risque de provoquer des interférences. L’énergie électromagnétique peut gêner le fonctionnement d’appareils électroniques comme des ordinateurs et des robots. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipe- ment électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précéden- tes, il incombe à l’utilisateur de prendre des mesures supplé- mentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protec- teurs dans la zone de travail. 2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des can- cers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation. Pour les moteurs à essence : Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres pro- blèmes de procréation. Pour les moteurs diesel : Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou au- tres problèmes de procréation.
OM-1327 Page 8 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet : www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site Internet : www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 11 West 42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site Internet : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superinten- dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet : www.osha.gov). 2-6. Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques. Le courant de soudage, pendant son passage dans les câbles de souda- ge, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs élec- triques à haute fréquence représente un risque à la santé humaine ». Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. Pour réduire les champs magnétiques sur le poste de travail, appliquer les procédures suivantes :
OM-1327 Page 9
Section 3 − Installation
3-1. Specifications Rated Output Max. Open Circuit 60 Hz Amps Input at Rated Output Rated Output Circuit Voltage 60 Hz200 V
230 V
460 V
575V
Kva
Kw
300 A at32 Vdc,
60% Duty 350 A at32 Vdc,
40% Duty 90 Single-Phase 69 (1.7*) 61 (1.5*) 30 (0.75*) 24 (0.5*) 13.1 11.2 60% Duty Cycle 40% Duty Cycle Three-Phase 34 (1.7*) 30 (1.5*) 15 (0.75*) 12 (0.5*) 11.6 11.550−700 Ipm
(1 3 17 8 m/min) H: 34 in (864 mm) W: 19 in (483 mm) 181 lb (82 kg) .023 − .045 in (0.8 − 1.1 mm) .030 − .045 in (0.8 − 1.1 mm) .035 − .047 in (0.9 − 1.2 mm) (1.3−17.8 m/min) W: 19 in (483 mm) D: 41 in (1041 mm) (82 kg) Operating Temperature Range: −20C to +40C Storage Temperature Range: -30C to + 50C 3-2. Duty Cycle And Overheating 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermistors open, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. Exceeding duty cycle can damage unit and void warranty. Overheating 0 15 A or VOr
Reduce Duty Cycle Minutes 60% Duty Cycle At 300 Amperes 40% Duty Cycle At 350 Amperes sduty1 5/95 / 217 442-A 4 Minutes Welding 6 Minutes Resting 10 15 20 25 30 40 50 60 70 80 90 100 100 150 200 225 250 300 400 500% Duty Cycle
Welding Amperes
OM-1327 Page 10 3-3. Volt-Ampere Curve
217 443-A
1 Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.Maxvolts
Minvolts
0 50 100 150 200 250 300 350 0 10 20 30 40 50 60 70 80 90Voltage
Amperage
3-4. Connecting To Weld Output Terminals803 778-A
Turn off power before connecting to weld output terminals. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your ma- chine. 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output ter- minal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean. Tools Needed: 3/4 in (19 mm) 4 2 3 Do not place anything between Correct Installation Incorrect Installation 1 weld cable terminal and copper bar.
OM-1327 Page 11 3-5. Installing Work Clamp 1 Work Cable 2 Boot Route cable through front panel opening. Slide boot onto work cable. 3 Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Close door.
803 540-B
Tools Needed: 3/4 in 3 2 1 3-6. Installing Welding Gun/Cable Holder 1 Welding Gun/Cable Holder 2 Wrapper 3 Slots Angle holder to insert hook through bottom slot. Drop holder down so that hook exits top slot. Ref. 803 545-B / Ref. 803 539-B 1 2 3
OM-1327 Page 12 3-7. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. Ref. 803 541-A 1 3 4 2
OM-1327 Page 13 3-8. Connecting Spoolmatic 15A Or 30A Gun
803 568-C
1 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 2 Weld Cable 3 Shielding Gas Hose Route weld cable and gas hose through opening in front panel. 4 Positive Weld Output Terminal Connect weld cable to weld output terminal. 5 Regulator/Flowmeter Route shielding gas hose through wire drive compartment, out opening in rear panel, and up to regulator/flowmeter. Connect gas hose to regulator/flowmeter. Tools Needed: 3/4, 5/8 in 5 3 4 2 1 2 3
OM-1327 Page 14 3-9. Connecting XR Edge, XR-A Gun, Or XR-A Python 803 569-A / Ref. 803 570 -A / Ref. 803 463 XR Edge guns prior to serial no. LE079101 require an adapter cord (part no. 195 498). 1 Gun End 2 Gun Liner 3 Wire Outlet Guide Trim excess liner from end of gun so no more than 3/32 in (2.4 mm) of liner extends past wire outlet guide. 4 Gun Securing Knob Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob. Be sure to change drive rolls to the proper size and type. 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 4 3 2 3/32 in (2.4 mm) Be sure to trim liner to proper extension. 1 5
OM-1327 Page 15 3-10. Setting Gun Polarity For Wire Type 1 Polarity Changeover Information Always read and follow manufacture’s recommended polarity. 1 3/4, 11/16 in Ref. 803 541-A Changing Polarity Wire Drive Assembly Lead Work Clamp Lead Positive Terminal Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW). Negative Terminal Electrode Negative (DCEN): Reverse lead connections at terminals from that shown above for gasless flux core wires (FCAW). Drive assembly becomes negative.
OM-1327 Page 16 3-11. Installing Gas Supply
803 542-A
Tools Needed: 1-1/8, 5/8 in 1 2 3 4 5 7 Rear Panel 6 Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Regulator/Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator/flowmeter gas hose connection, and fitting on rear of welding power source. 7 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate. Argon Gas Or Mixed Gas Regulator/Flowmeter for 350P model shown. DO NOT use Argon/Mixed gas regulator/flowme- ter with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter. 3-12. Installing Wire Spool and Adjusting Hub Tension072573-B
When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. Tools Needed:
OM-1327 Page 17 3-13. Electrical Service Guide 60 Hz Single Phase 60 Hz Three Phase Input Voltage 200 230 460 575 200 230 460 575 Input Amperes At Rated Output 69 61 30 24 34 30 15 12 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1, Time-Delay 2 80 70 35 25 40 35 15 10 Normal Operating 3 100 90 40 35 50 45 20 15 Min Input Conductor Size In AWG 4 6 8 10 12 10 10 14 14 Max Recommended Input Conductor Length In Feet (Meters) 101 (31) 86 (26) 229 (70) 217 (66) 86 (26) 114 (35) 178 (54) 277 (85) Min Grounding Conductor Size In AWG 4 8 8 10 12 10 10 14 14 Reference: 2005 National Electrical Code (NEC) (including article 630) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse. 2 “Time-Delay” fuses are UL class “RK5” . 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source. Caution: This unit is either a 200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label.
OM-1327 Page 18 3-14. Selecting Input Voltage (200/230/460 Volt Models Only)
803 539-B / 804 042-A
Turn Off welding power source, disconnect input power, and check voltage on input capacitors according to Section 6-3 before proceeding. Check input voltage available at site. Incorrect linking can damage unit and void the warranty. 1 Voltage Selection View Window Check voltage selected in unit. Changing selection is only neces- sary if selected value does not match available input voltage. 2 Relinking Board PC6 3 Mounting Screws 4 Receptacle RC23 (Connection For 230 VAC Input Power) 5 Receptacle RC46 (Connection For 460 VAC Input Power) Move relinking board as needed and connect plug PLG32 (in unit) to RC23 or RC46 according to input power voltage. 1 Tools Needed: 5/16 in Be sure to reinstall all four screws securing relinking board in place. 2 3 4 3 5
OM-1327 Page 19 3-15. Selecting A Location And Connecting 3-Phase Input Power Ref. 803 543-C / 803 766-A Installation must meet all National and Local Codes - have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. Caution: This unit is either a 200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label. 1 Rating Label 2 Input Power Cord 3 Disconnect Device (switch shown in the OFF position) 4 Green Or Green/Yellow Grounding Conductor 5 Disconnect Device Grounding Terminal 6 Input Conductors (L1, L2 And L3) 7 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1, L2, and L3 to disconnect device line terminals. 8 Over-Current Protection Select type and size of over-current protection using Section 3-13 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. Tools Needed: 2 1 Rear Panel 18 in (457 mm) for airflow Do not move or operate unit where it could tip. = GND/PE Earth Ground 3 3 4 5 7 6 8
L1
L2
L3
OM-1327 Page 20 3-16. Selection A Location And Connecting 1-Phase Input Power Ref. 803 543-C / 803 766-A Tools Needed: 3 2 7 6 4 Installation must meet all National and Local Codes - have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors form unit. Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. Caution: This unit is either a 200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label. Three Conductor Power Cord Preparation 1 Rating Label 2 Input Power Cord 3 Black And White Input Conductors (L1 And L2) 4 Red Input Conductor 5 Green Or Green/Yellow Grounding Conductor 6 Insulation Sleeving 7 Electrical Tape Insulate and isolate red conductor as shown. Disconnect Device Input Power Connections 8 Disconnect Device (switch shown in the OFF position) 9 Disconnect Device Grounding Terminal 10 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor (see Item 6) to disconnect device grounding terminal first. Connect input conductors L1 and L2 to disconnect device line terminals. 11 Over-Current Protection Select type and size of over-current protec- tion using Section 3-13 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. 5 2 1 Rear Panel 18 in (457 mm) for airflow Do not move or operate unit where it could tip. =GND/PE Earth Ground 8 1 5 3 9 10 11
L1
L2
OM-1327 Page 21 3-17. Threading Welding Wire For Roughneck Gun 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide 6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 6 in (150 mm) Hold wire tightly to keep it from unraveling.
Wood
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Close and tighten pressure assembly, and let go of wire. Remove gun nozzle and contact tip. Turn On. Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close and latch door.803 570-A / 803 544-A / S-0627-A
Tighten 1 2 3 4 Use pressure indi- cator scale to set a de- sired drive roll pres- sure. Pressure Indicator Scale Tighten 1 2 3 4 7 8 3 5 6 2 1 4
OM-1327 Page 22 3-18. Threading Welding Wire For XR Edge, XR-A Gun, Or XR-A Python 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide 6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 6 in (150 mm) Hold wire tightly to keep it from unraveling. Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Close and tighten pressure assembly, and let go of wire. See Section 3-19 for threading welding wire through XR guns. Ref. 803 544-A / 218 243-A / 218 244-A / S-0627-A Tighten 1 2 3 4 Use pressure indicator scale to set front drive roll pres- sure to 1 and rear drive roll pres- sure to less than 1. Pressure Indicator Scale
218243−A
Important!
For Aluminum Push−Pull welding. Thread hub tension nut looselyImportant!
For Aluminum Push−Pull welding. 1 2 3 4218244−A
7 8 3 5 6 2 1 4
OM-1327 Page 23 3-19. Threading Welding Wire Through XR Guns Ref. 802 193-A / 801 556 / Ref. 151 666-C Tools Needed: Welding wire is electrically live when gun trigger is used to jog wire. Refer to Section 3-18 for instruc- tions on feeding wire through welding power source. 1 Pressure Roll Assembly Lay gun cable out straight. Open top cover, and open pressure roll as- sembly. If not already done, remove gun barrel assembly. Press gun trigger until about 4 in (102 mm) of wire is sticking out front of gun. Insert wire into barrel liner and tighten barrel as- sembly. Install correct size contact tube and install collet nut. Close top cover on gun. Press trigger switch until about 6 in (152 mm) of wire is sticking out end of contact tip. Cut off wire. Close and latch door. XR Edge gun drive roll pressure should be set at minimum. Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Do not exceed midrange setting. Cut off wire. Close and latch door. Turn welding power source Off. Nonconductive Surface For XR-A Edge Gun: For XR-A Pistol Gun: For XR-A Pistol Gun: 1 Pressure Roll Assembly 2 Drive Roll 3 Thumbscrew Lay gun cable out straight. Open top cover, and lift pressure arm and open pressure roll assembly. If not already done, remove gun barrel assembly. Manually thread wire along drive roll groove. Close pressure roll assembly. Press gun trigger until about 4 in (102 mm) of wire is sticking out front of gun. Insert wire into barrel liner and tighten barrel as- sembly. Install correct size contact tube and install collet nut. Reinstall gun cover. 4 Pressure Adjustment Knob See final pressure adjustment at bottom of page. 1 2 Turn On Welding Power Source. Turn On Welding Power Source. 1 3 Remove barrel assembly before threading wire through gun. Remove barrel assembly before threading wire through gun.
OM-1327 Page 24
Section 4 − Operation
4-1. Controls 1 Pulse Indicator Light Pulse only lights if unit has the pulse MIG module and is programmed for pulse MIG. 2 MIG Indicator Lights Pulse (1) and MIG (2) illuminate to Indicate weld mode of unit. 3 Process Light PROCESS illuminates when unit is in Process select menu. 4 Wire Light WIRE illuminates when unit is in Pulse MIG program select menu. 5 Timers Light TIMERS illuminates when unit is in Timers menu. 6 Setup Button Use button to access Timers, Process and Wire menus. 7 Arc Control Button Use button to select either inductance control in MIG welding mode or Sharp Arc in Pulse MIG welding mode. 8 Left Knob Use knob to adjust volts in MIG welding mode or change parameter values in Setup. 9 Right Knob Use knob to adjust wire speed in MIG welding mode or change parameter values in Setup. 10 Left Display 11 Right Display 12 Weld Functions/Setup Indicator Lights VOLTS illuminates in MIG welding mode indicating volts in left display can be adjusted. Also, VOLTS lights to indicate left display is showing actual voltage during welding and for 5 seconds after the arc is extinguished. ARC LENGTH illuminates in Pulse MIG welding mode indicating Arc Length can be adjusted. SETUP illuminates when a parameter on the corresponding display above the light can be adjusted. WIRE SPEED illuminates in either Pulse MIG or MIG welding mode indicating wire speed can be adjusted. AMPS illuminates indicating welding amps appears in the display, instead of wire speed, during welding and for 5 seconds after the arc is extinguished. 1 11 Ref. 213 935-A 9 8 6 5 4 3 10 12 7 2 The first time the welding power source is energized it starts in MIG welding mode. Each time after the initial startup, when the unit is turned off, whatever mode and parameter settings were last set will remain as the current settings the next time the unit is energized.Note
4-2. MIG Mode In MIG mode, VOLTS is lit under left display and WIRE SPEED is lit under right display. Left knob is used to adjust welding voltage within a range of 14-32 volts, and right knob is used to adjust wire feed speed within a range of 25-700 IPM. Refer to weld chart in front compartment for proper parameter settings according to wire type, shielding gas, and material type and thickness.
OM-1327 Page 25 4-3. Jog Mode If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld power. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow because gas valve is located inside spool gun. For MIG guns, wire will feed for up to 2 minutes while trigger is pressed, then wire drive system in unit will automatically shut off. For spool guns, wire will feed for up to 30 seconds before shutting off. If gun trigger is pressed for 3 seconds without striking an arc the displays will show JOG MODE. 4-4. Weld Status When trigger is released on a MIG gun, spool gun, or push-pull gun, the last actual amperage and voltage will be shown on the displays for 5 seconds. The VOLTS and AMPS indicator lights will illuminate under the displays and each value will appear in the corresponding display. If a programmed value requires adjustment after the arc is extinguished and during the 5 seconds display of actual values, turning either knob will cause actual values in the displays to be replaced by programmed values for adjustment purposes. The 5 second delay after the arc is extinguished for displaying actual weld values can be turned on or off in the Timer menu DISP selection (see Section 5-3).
Note
4-5. MIG Gun-On-Demand The guns that can be used with this unit are MIG guns, spool guns, and push-pull guns. To switch from one gun to another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun. If the unit is powered down and back on again, the gun last used will become the current active gun. 4-6. Pulse MIG Mode Voltage Adjustment In Pulse MIG mode there is no manual voltage adjustment; instead, voltage is synergically aligned with the proper wire feed speed. Arc Length adjustment is used to adjust actual arc length which automatically adjusts the voltage. See weld chart in front compartment for proper wire feed speed adjustment according to wire size and type. 4-7. Pulse MIG Gun-On-Demand The spool gun functions slightly different in Pulse MIG mode. To switch from one gun to another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun. For a spool gun, the wire speed is taken from the position of the gun potentiometer. This wire speed value is automatically adjusted if the potentiometer is moved since the last time the gun was active. If the unit is powered down and back on again, the gun last used will become the current active gun. 4-8. Tip Saver If gun contact tip is directly shorted to the workpiece while gun trigger is pressed, the welding arc automatically shuts off after 1 second to prevent wire burnback in the contact tip.
OM-1327 Page 26 4-9. Weld Parameters For MIG And Pulse Mode Material Steel Steel Aluminum Stainless Steel Gas 100% Co 2 75% Argon 25% Co 2 90% Helium 7.5% Argon 2.5% Co 2 100% Argon Wire 1/2” 3/8” 1/4” 3/16” 1/8” 14ga 16ga 18ga 20ga 22ga 3/64 5356 24.0/535 23.5/500 22.5 /465 21.0 /375 19.0 /340 .035 4043 3/64 4043 .035 5356 − 23.5/700 18.2/300 24.0/475 23.5/435 23.0/375 21.5/305 19.5/250 − Inductance = 20−40 23.5 /220 Volts/Wirefeed Reference Inductance = 20−40 Inductance = 60−80 Inductance = 30 .035 .035 .045 − 23.0 /325 21.5 /280 20.5 /240 20.0/210 19.0 /175 18.5/160 18.0/115 17.0/90 16.5/80 28.5 /485 19.5 /330 18.5 /275 18.0 /260 16.5 /200 16.0/155 15.5/135 15.0/100 14.5/95
Use
Spray
19.0/220 18.0 /200 17.5 /170 16.2 /150 16.0/130 15.5/100 − 24.0/400 23.0/300 20.5/250 20.0/235 19.5/175 19.0/160 .045 .045 .035 − 23.0 /220 21.5 /200 20.5 /175 20.0 /150 19.0 /110 18.5/105 − − − − 25.0 /450 22.5/440 21.5 /375 21.0/325 20.0/275 18.0/235 18.5/200 17.5/150 − 29.3/530 (12.7mm) (9.5mm) (6.4mm) (4.8mm) (3.2mm) (2.0mm) (1.6mm) (1.2mm) (0.9mm) (0.8mm) Note: All chart parameters reference settings for Horizontal T fillet welds. Settings may need to be modified for other types of welding joints or welding positions.Mig Chart
Mig Chart
Metal Core Inductance = 30 .045 26.0/400 24.5/350 23.5/300 90% Argon 10% Co 2 − − − − − − − − − 27.0/425 29.0/475 .045 .045 3/644043 3/645356 .0355356WeldCharts
3/16" (4.8mm) 1/8" (3.2mm) 14ga (2.0mm) 16ga (1.6mm) 18ga (1.2mm) 19ga (1.0mm) 22ga (0.8mm) Gas Wire Material 90%Argon 10%Co2 .035 Steel Ar/He/CO2 Tri−Mix .035 StainlessSteel .0354043 1/2" (12.7mm) 500 450 450 650 600 750 3/8" (9.5mm) 450 350 390 550 550 500 650 1/4" 300 200 325 405 720 400 400 550 200 150 260 350 640 300 300 450 150 125 200 290 450 250 200 310 125 100 140 190 310 200 175 210 100 75 110 165 245 150 150 185 75 50 90 115 200 85 100 150 75 150 130 100%Argon AluminumPulseChartPulseChart
(6.4mm) All chart parameters are based on the following defaults: arc length −50, Sharparc −25. 90%Argon 10%Co2 .045 MetalCore 475400 325250 200 150 125 115
OM-1327 Page 27 Notes
OM-1327 Page 28 4-10. Recommended Crater Fill Parameters 1/2" (12.7mm) What Process are You Using? What Material are You Welding? Suggested Wire Types Suggested Shielding Gases Wire Sizes (Diameter) Recommended Crater Parameters
P
U
L
S
E
M
I
G
OM-1327 Page 29
Sc-187 212-A
19ga. 20ga. (0.9mm) (1.05mm) 3/8" 1/4" 3/16" 1/8"
OM-1327 Page 30
Section 5 − Programming
5-1. MIG Welding Mode When the MIG light (2) is illuminated, the unit is in MIG Welding mode.Setup
To enter MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select the gun being used. Select MIG for standard MIG gun, or select XR-A, EDGE, PYTH for push pull guns, or SPL for spoolgun. Depress SETUP (6) a second time to illuminate the PROCESS (3) light. Rotate right knob (9) until MIG is displayed (for MIG only units NOT USED will be displayed). Depress SETUP (6) button again to illuminate the WIRE (4) light. This menu is not used in MIG Welding mode. Depress SETUP (6) button again to illuminate TIMERS (5) light. For description of the TIMERS, refer to TIMERS menu (see Section 5-3) If crater fill function menus are enabled, TIMERS light will stay on to allow for adjust- ment of crater parameters and timers (see Section 5-5). Depress SETUP (6) button again to exit menus and enter MIG welding mode.Operation
Adjust welding Voltage with left knob (8) and Wire Feed Speed with right knob (9). Refer to MIG welding chart for proper Voltage and Wire Feed Speed setting in reference to material type, material thickness, wire, and gas (see Section 4-9).Arc Control
MIG welding mode: Depress ARC CONTROL (7) button to enter Arc control menu and INDU will appear on the left display and the corresponding setting will appear on the right display. Adjust right knob (9) to adjust inductance setting. In MIG welding mode the Arc control is an inductance control from 0-99. Refer to MIG welding chart for suggested Inductance setting for the wire and gas types being used (see Section 4-9). Changing the inductance will change the fluidity of the puddle. Low Inductance High Inductance Weld Bead Weld Bead (0 setting) 99 setting Ref. 213 935-A 1 7 9 8 2 3 4 5 6
OM-1327 Page 31 5-2. Pulse MIG Welding Mode When the PULSE MIG (1, 2) is illuminated, the unit is in Pulse MIG Welding mode.
Setup
To enter Pulse MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select the gun being used. Select MIG for standard MIG gun, or select XR-A, EDGE, PYTH for push pull guns, or SPL for spoolgun. Depress SETUP (6) a second time to illuminate the PROCESS (3) light. Rotate right knob (9) until PULS is displayed. Depress SETUP (6) button again to illuminate the WIRE (4) light. Adjust left knob (8) to select wire type, adjust right knob (9) to select wire size. Depress SETUP (6) button again to exit WIRE menu and enter TIMERS (5) menu. The TIMERS (5) light will illuminate. For description of the TIMERS, refer to TIMERS menu (see Section 5-3) If crater fill function menus are enabled, TIMERS light will stay on to allow for adjust- ment of crater parameters and timers (see Section 5-5). Depress SETUP (6) button again to exit menus and enter PULSE welding mode.Operation
Adjust right knob (9) for proper Wire Feed speed and adjust left knob (8) to change Arc Length if required. Arc length will de- fault to 50 if never adjusted previously. Re- fer to Pulse MIG welding chart for proper Wire Speed setting for metal and metal thickness being welded (see Section 4-9). All Pulse MIG programs are setup with the gases listed in the Pulse MIG welding chart. If alternate gases are used, adjust Arc Length and/or Sharp Arc (Arc Con- trol) (7) to adjust arc characteristics.Arc Length
Arc length can be adjusted from 0-99. All Pulse MIG programs are set with a value ofArc Control
Pulse MIG (1, 2) welding mode: Depress ARC CONTROL (7) button to enter Arc Control menu for sharp arc. SHRP will ap- pear on the left display and the correspond- ing setting will appear on the right display. The setting can be adjusted from 0-50 and all Pulse MIG welding programs are de- signed with a setting of 25. Adjusting the Sharp Arc setting will vary the width of the welding arc cone. (0 Setting) (50 Setting) Low Setting High Setting If a gas is used other than what is listed on the Pulse MIG welding program chart, the Sharp Arc can be adjusted to help custom- ize your arc to the gas being used. Ref. 213 935-A 1 7 9 8 2 3 4 5 6
OM-1327 Page 32 5-3. Timers To enter the TIMERS (5) menu depress the SETUP (6) button 4 times or until the TIMERS light (5) is illuminated. Items that can be adjusted in this menu are: Run-in speed (R-IN) − The speed of the wire prior to the welding arc being struck. This setting is a percentage of the Wire Feed Speed the unit is set to for welding. Programming value ranges from 25-150. Preflow (PRE) − The amount of time that the shielding gas will flow after the trigger is depressed and before the welding arc will be allowed to be active. Range of setting is from 0-5 seconds. Postflow (POST) − The amount of time that the shielding gas will flow after the arc has been shut off. Range of setting is 0-10 seconds. Spot Timer (SPOT) − The amount of time that the arc will be active before it shuts off automatically. Range of setting is from 0-120 seconds. Spot timer is reset upon re- lease of welding gun trigger. Display (DISP) − Allows the Wire Speed display to show actual welding amperage while arc is active and for 5 seconds after arc is shut off. Setting is either AMPS or WFS for standard Wire Feed Speed. Once in the TIMERS (5) menu, rotate the left knob (8) to find a particular item, and ro- tate the right knob (9) to change setting or status. Depress SETUP (6) button to get out of TIMERS (5) menu and to enter welding mode. Ref. 213 935-A 1 9 8 2 3 4 5 6 7
OM-1327 Page 33 5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill Arc times and number of arc starts are saved in unit memory. To view this information, press both SETUP (1) and ARC CONTROL (2) buttons at the same time. Left display will initially show arc hours. Rotate left knob (3) and display will change to show number of arc starts. To turn on the Crater Fill display, rotate left knob (3) until CRTR appears in the left display. The factory default for Crater Fill display is OFF which appears in the right display. Rotate the right knob (4) until ON appears in the display. The Crater Fill display can be turned off after parameters are set in programs, but remember that once crater fill is turned on in any program, it will remain on even though it does not appear in the displays because Crater Fill display is turned off. To exit this menu, press either the SETUP (1) or ARC CONTROL (2) button, or press a gun trigger on any welding gun connected to the unit. Ref. 213 935-A 4 1 2 Accessing the Arc Times, Arc Starts, Hot Start (aluminum pulse only), and Crater Fill data will also allow access to Software Version data and Motor Calibration function. The software version data and motor calibration function are for use by factory authorized service personnel only. Do not use the motor calibration function if it appears on the displays. 3
OM-1327 Page 34 5-5. Setting Crater Fill To set Crater Fill, select a program and press SETUP (1) until the TIMERS LED turns on. Press SETUP again and the left display will show CRTR and the right display will show OFF. Rotate right knob (3) to turn crater ON. Rotate left knob (2) to change display to WFS, and rotate right knob (3) to set crater wire feed speed. Wire feed speed range is 50-700 IPM (see Section 4-10). Rotate left knob (2) to change display to TIME, and rotate right knob (3) to set crater time. Time range is 0.1-5.0 seconds (see Section 4-10). Rotate left knob (2) to change display to VOLT (MIG program) or ARCL (pulse program), and rotate right knob (3) to set either volts (range is 10.0-32.0 volts) or arc length [range is 0-99 (see Section 4-10)]. Rotate left knob (2) to change display to TDLY for time delay. This setting is for spot or skip welding without crater fill if the arc time is less than the set time. Time range is 0.0-5.0 seconds (i.e. if TDLY is set for 2.0 seconds, weld operation will not go into crater if gun trigger is released before 2.0 seconds). To exit this menu, press the SETUP (1) button. Ref. 213 935-A 3 1 Crater parameters are welding gun independent (i.e. crater fill can be on for a spool gun and off for a MIG gun). When using the same welding gun, MIG and pulse programs are independent of each other; however, crater parameters will be the same for all pulse programs. For example, if a MIG gun is using the .035 steel pulse program, and crater fill is on and parameters are set, crater will also be on and the same parameters will be set for a stainless pulse program. 2
OM-1327 Page 35 5-6. Setting Hot Start (Aluminum Pulse Only) Parameters To access the Setup Feature Menu, press both SETUP (1) and ARC CONTROL (2) buttons at the same time. Left display will initially show arc hours. Rotate left knob (3) until ALST appears in the left display. Rotate right knob (4) to select hot start mode as follows: Auto − default setting for preset hot start parameters Off − hot start is inactive On − allows customized setting of hot start parameters Manual Hot Start Mode When ALST appears in the left display and On appears in the right display, the welding power source is set for manual hot start mode. To access hot start parameters, press the SETUP (1) button until SPWR appears in the left display. SPWR − Start Power Range for start power is 100-250 as a per- cent of wire feed speed. SPWR maximum setting will de- pend on set wire feed speed and may not allow a setting of 250 under certain conditions. STMR − Start Time Time range is 0.0-0.5 seconds for hot start to be on. STRL − Start Arc Length Range for start arc length is 0-99 that changes arc length from shorter to longer. RMPT − Ramp Time Time range is 0.1-5.0 for the time it takes to go from hot start to set wire feed speed. The two parameters that will have the largest influence on hot start are Start Power and Start Time. These two parameters will determine how much heat is provided and for how long at the beginning of the weld. To exit this menu, press the SETUP (1) button. Ref. 213 935-A The factory default setting for Hot Start is “Auto” on 350P models. The Auto setting has preset parameters. Hot Start can also be set to “On” (manual) for customized settings or made inactive when set to Off. 4 1 2 3
OM-1327 Page 36 5-7. System Reset A system reset function is available that completely resets unit back to all the original factory settings. To access this menu, turn on welding power source, then press the SETUP (1) button when the SETUP light illuminates under the Left display. SRST will appear on the left display and OFF will appear on the right display. To prepare the unit for system reset, rotate right knob until ON appears on the right display. To apply the system reset function, press SETUP (1) button, and wait until unit completely reboots before performing any other operations. Ref. 213 935-A 1 Accessing the System Reset function will also allow access to Timer Reset (RTMR) and Option Reset (ORST) functions. The timer reset and option reset functions are for use by factory authorized service personnel only. Do not use the timer reset or option reset functions if they appear on the displays.
OM-1327 Page 37
Section 6 − Maintenance &Troubleshooting
6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals Check gun cable. 6 Months Blow out or vacuum inside.Or
Clean drive rolls. 6-2. Overheating Thermistors RT1 and RT2 protect the unit from damage due to overheating. If output diode heatsink or IGBT heatsink gets too hot, RT1 and/or RT2 opens and output stops. The fan keeps running to cool the unit. Wait several minutes before trying to weld.
OM-1327 Page 38 221 044-A / Ref. 803 550-A Significant DC voltage can remain on capacitors after unit is Off. Always check ca- pacitors as shown to be sure they have discharged before working on unit. Turn Off welding power source and disconnect input power. Remove case. 1 Input Capacitor C3 Terminals 2 Input Capacitor C4 Terminals 3 Voltmeter Check input capacitors as shown. Measure the dc voltage across the positive (+) and negative (−) terminals until voltage drops to near 0 (zero) volts. Proceed with job inside unit. Reinstall case when finished. Tools Needed: 5/16 in 3 6-3. Measuring Input Capacitor Voltage 3 2 1
OM-1327 Page 39 6-4. Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Intermediate Guide 4 Drive Roll The drive assembly comes equipped with factory installed .035/.045 combination drive rolls. Be sure that all 4 drive rolls are installed correctly. Combination drive rolls consist of two different sized grooves. The stamped markings on the end sur- face of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the carrier gear is the groove for the wire size viewed on the end surface of the drive roll. Install correct drive roll for wire size and type. U-Grooved drive rolls are required for feeding aluminum wire. 5 Drive Roll Securing Nut Turn nut one click to secure drive roll. 1 2 4 5 Tools Needed: 5/64 in 7/16 in
802 520-B
1 3 Stamped .035 Stamped .045 .045 Groove .035 Groove
OM-1327 Page 40 6-5. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-15 or 3-16). Replace building line fuse or reset circuit breaker if open (see Section 3-15 or 3-16). Secure gun trigger connections (see Section 3-7). Have Factory Authorized Service Agent check Power switch. Have Factory Authorized Service Agent check all board connections and main control board. No weld output; wire feeds. Thermistor RT1 or RT2 open (overheating). Allow fan to run; the unit will be enabled when it has cooled and temperatures are within acceptable limits (see Section 3-2 and 6-2). Connect work clamp to get good metal to metal contact. Replace contact tip (see gun Owner’s Manual). Have Factory Authorized Service Agent check main control board and main rectifier. Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 3-15 or 3-16). Have Factory Authorized Service Agent check main control board and user interface board. Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1). Change to correct size drive rolls (see Section 6-4). Readjust drive roll pressure (see Section 3-17). Replace inlet guide, contact tip, and/or liner if necessary (see gun Owner’s Manual). Have Factory Authorized Service Agent check input voltage. Have Factory Authorized Service Agent check main control board. No wire feed. Turn Wire Speed control to higher setting (see Section 4-1). Clear obstruction in gun contact tip or liner (see gun Owner’s Manual). Readjust drive roll pressure (see Section 3-17). Change to correct size drive rolls (see Section 6-4). Rethread welding wire (see Section 3-17). Check gun trigger and leads. Repair or replace gun if necessary. Have Factory Authorized Service Agent check main control board and user interface board. H − − message appears on voltmeter and ammeter displays to indicate thermistor RT1 or RT2 is open and unit is in an overheated condition (see Section 6-6).
OM-1327 Page 41 6-6. Help Displays
A
V
A
V
A
V
Help
0A
V
A
V
A
V
A
V
A
V
A
V
A
V
Help
1Help
2Help
3Help
4A
V
Help
5A
V
Help
6Help
8Help
9Help
10Tip
Save
Mm
350P
A
V
Mm
350A
V
Jog Mode
A
V
Help
7A
V
Help
11
OM-1327 Page 42
Sc-187 212-A
All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 0 Indicates overheating on left side of unit (displays flash between OVER TEMP and HELP 1). Unit will shutdown until internal temperature drops within operational range. Help 1 Indicates communication lost between control board PC1 and user interface board. Turn off input primary power and check input voltage per primary voltage rating of welder. Help 2 Indicates overheating on right side of unit (displays flash between OVER TEMP and HELP 2). Unit will shutdown until internal temperature drops within operational range. Help 3 Indicates gun trigger was pulled and held during power up. Release gun trigger and clear fault condition. Also, this display can Indicate no open circuit voltage detected when gun trigger is pulled and no arc detected within 3 seconds. Turn off primary input power and contact a Factory Authorized Service Agent. Help 4 Indicates gun trigger was pulled and held for 2 minutes without a welding arc established or there is a direct short between contact tip or wire and the workpiece. Release gun trigger and clear fault condition. Help 5 Indicates a malfunction in wire feed system and/or drive motor overcurrent condition. Check for proper spool brake adjustment or obstructions in wire feed system. Clean or replace liner, wire guides, or contact tip. Help 6 Indicates a malfunction in wire feed system and/or external drive motor overcurrent con- dition (spool gun or push-pull gun). Check for proper spool brake adjustment or obstructions in wire feed system. Clean or replace liner, wire guides, or contact tip. Help 7 Indicates input voltage malfunction (voltage too high or too low) causing unit to automatically shut down. Turn off input primary power and check input voltage per primary voltage rating of welder. Unit will operate once input voltage is within specification and power to unit is turned off and back on. Help 8 Indicates a malfunction in the secondary power circuit of the unit. Check control board PC1, and primary and secondary connections. Help 9 Indicates a malfunction in Pulse MIG function. Check connection between pulse board and user interface board. Replace pulse board, if necessary. Help 10 Indicates a trigger error when two gun triggers are activated at the same time. Release gun triggers to clear error. Help 11 Indicates a tach error when tach feedback signal is not present. Release and press gun trigger to reset tach signal. If error continues, contact a Factory Authorized Service Agent. Tip Save Indicates contact tip is directly shorted to workpiece. Arc shuts off in this condition, and message resets when tip is not touching workpiece and gun trigger is released.Mm 350P
When unit is turned on, this display indicates that pulse option is installed and operational.Mm 350
When unit is turned on, this display indicates that unit is either a MIG only machine or pulse option is installed but not operational. Jog Mode Indicates trigger is pressed, but no arc is detected. Wire feed speed goes to Jog mode speed after 3 seconds.
OM-1327 Page 43 Notes
OM-1327 Page 44
Section 7 − Electrical Diagram
Figure 7-1. Circuit Diagram For 200V/230V/460V Models
OM-1327 Page 45
224 242-A
OM-1327 Page 46 Figure 7-2. Circuit Diagram For 460V/575V Models
OM-1327 Page 47
223 926-A
OM-1327 Page 48
Section 8 − Parts List
803 545-C
Hardware is common and not available unless listed. 1 2 3 5 6 7 9 13 12 16 17 19 20 21 22 23 24 25 26 4 28 29 15 14 18 8 − Fig. 8-2 11 − Fig. 8-5 10 − Fig. 8-3 27 − Fig. 8-4 Figure 8-1. Main Assembly
OM-1327 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 212829
Door,Access Wire Compartment
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Neg
097416Terminal,Pwr Output Black
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Pos
097421Terminal,Pwr Output Red
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C6,7
213038Capacitor Assy
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Hd1
189567Transducer,Current 400A Module Supply V +/− 15V
1 . . . . . . . . . . . . . . . . . . . . 183046Cable,Lem
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 221326Bus Bar,Current Sensor
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 199824Label,Warning Electic Shock And Pinch Points
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fig 8-2Baffle,Center
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 212821Panel,Front Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fig 8-3Inverter Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 +Fig 8-5Panel,Rear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 134464Label,Warning General Precautionary Static&Wire
1 . . . . . . . . . . . . . . . . . . . . . . . 13 212826Door,Access Tool Compartment
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 217829Latch,Door Straight Loop Catch
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 215061Gun/Cable Holder
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 +222288 PANEL,SIDE RH LOWER (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180994 LABEL,WARNING MATCH INPUT POWER (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 222325 LABEL,WARNING INPUT POWER RELINK (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 17 213939Label,Warning Electric Shock Can Kill Significant
1 . . . . . . . . . . . . . . . . . . . . . . . . 18 +222287 WRAPPER (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 +212823 WRAPPER (460/575V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 186758Wheel,Polypropylene 10 In X 2.25 Wide
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 602250Washer,Flat .812Idx1.469Odx.134T Stl Pld Ansi.750
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 121614Ring,Rtng Ext .750 Shaft X .085 Thk E Style Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 213903Rack,Cylinder Single
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 212833Base,
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 209870Caster,Swvl 4.00 In X 1.250 In Poly−Olefin
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Fm
213043Fan,Muffin 24Vdc 3000 Rpm W/20.500 In Leads
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 212846Bezel,Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Fig 8-4Panel,Front
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 212822Panel,Side Lh Lower
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 151187Latch,Slide Flush Mtg Hole 1.000 Widex 1.500 Lg
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194755Roughneck C−4012 Gun
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209123Regulator/Flowmeter,10−50 Cfh Argon/Mix (350 Model)
1 . . . . . . . . . . . . . . . . . . . . . . . 210925Regulator/Flowmeter,0−50 Cfh Ar/Co2
. . . . . . . . . . . . . . . . . .W/Flowtube(350P Model)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144108Hose,Gas 5Ft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196329Cable,Work 10 Ft No1 W/Clamp & Boot
. . . . . . . . . . . . . . . . . .(350 Model) (Including)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130750Clamp,Work 300 Amp
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196318Cover,Cable Btry Post Blk .75 Id
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213369Cable,Work 10 Ft 1/O W/Clamp & Boot
. . . . . . . . . . . . . . . . . .(350P Model) (Including)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213619Clamp,Work 300 Amp Stl Chrome Pld W/Cop Contacts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 196318Cover,Cable Btry Post Blk .75 Id
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206186Tip,Fastip .312 Od .035 And .030Al Wires
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206188Tip,Fastip .312 Od .045 And .040Al Wires
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦212492Regulator/Flowmeter, 0−50 Cfh Co2
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +When ordering a component originally displaying a precautionary label, the label should also be ordered.♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 50
803 546-B
Hardware is common and not available unless listed. 1 3 2 4 5 6 7 8 9 10 12 13 14 15 16 13 17 18 11 Figure 8-2. Baffle, Center w/Components Description Part No. Dia. Mkgs. Item No. Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7) Quantity 1 058427Ring,Retaining Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 085980Nut,Stl Hex Full .625-11
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 605941Washer,Flat Stl .640 Id X 1.000 Od X 14Ga Thk
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 186437Spring,Cprsn .845 Od X .110 Wire X 1.500
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 057971Washer,Flat Stl Keyed 1.500Dia X .125Thk
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 057745Spring,Cprsn 2.305 Od X .090 Wire X 2.500 Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 186435Hub,Spool
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 186436Washer,Brake Plastic
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 198425Cap,Finishing 1.19 X .37
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 198426Washer,Cap
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 223921Baffle,Center
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 177307Reel Support
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 134201Stand−Off Support,Pc Card .312/.375W/Post&Lock .43
9 . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7) (Continued) Quantity 14
Pc1
223542 KIT,MM350 CONTROL BOARD W/ INSTRUCTIONS (200/230/460V model) 1 . . . . . . . . . 14Pc1
223670 KIT,MM350 CONTROL BOARD W/ INSTRUCTIONS (460/575V model) 1 . . . . . . . . . . . . .Plg7
115092Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg8
131056Housing Rcpt+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg10,14 115091
Housing Plug+Skts,(Service Kit)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg11,17 131054
Housing Plug+Skts,(Service Kit)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg12,13,
. . . . . . 16 131204Housing Plug+Skts,(Service Kit)
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213404Cable,Interconnecting Rs 485 Interface To Control
1 . . . . . . . . . . . . . . . . . . . . . . . . . 213405Cable,Interconnecting Rs 485 Interface To Pulse Op
1 . . . . . . . . . . . . . . . . . . . . . . . . . 168674Cable,Ribbon 24 Posn 14.000 In Skts Be Inverted
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pc6
216342Circuit Card Assy,Gmaw Pulse W/Program
. . . . . . . . .(Pulse Model Only)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg29
131204Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg30
115091Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 212843Housing,Adapter Drive Motor
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fig 8-6Drive Assy,Wire 4 Roll
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 204310Stand−Off,No 6−32 X .437 Lg .250 Hex Al M&F
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 52
803 552-A
Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 11 13 14 16 18 21 20 19 22 23 24 25 26 17 27 28 29 30 31 32 33 12 15 10 Figure 8-3. Inverter Assy Description Part No. Dia. Mkgs. Item No. Figure 8-3. Inverter Assy (Fig 8-1 Item 9) Quantity 1W
188634Contactor,Def Prp 60A 3P 24Vac Coil W/Cover
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .C11,12,
. . . . . . . 13 148240Capacitor,Cer Disc .003 Uf 2000 Vac W/Terms
3 . . . . . . . . . . . . . . . . . . . . . . 2 +212750Windtunnel,Lh
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185835Label,Warning Electric Shock/Exploding Parts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3T1
180952Xfmr,Hf
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L1
222392 INDUCTOR,INPUT (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L1
216006 INDUCTOR,INPUT (460/575V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Z1
212756Stabilizer,Output
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Sr1
212937Kit,Diode Power Module
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7T2
224238Xfmr,Control 200/230/460 Pri
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7T2
223922Xfmr,Control 460/575 Pri
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg26
168071Housing Plug Pins+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 +212752Windtunnel,Rh
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Cr1
106462Relay,Encl 24Vdc Dpdt 20A/120Vac 8Pin Flange Mtg
1 . . . . . . . . . . . . . . . . . . . . . 10 177547Bushing,Snap−In Nyl Ct−Mount 1.125 Mtg Hole
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Ct1
213032Xfmr,Current
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 025248Stand−Off,Insul .250−20 X 1.250 Lg X .437 Thd
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C1
186015Capacitor,Polyp Film .34 Uf
. . . . . . . . . . . 1000 VAC +8% −0% (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C1
193858 CAPACITOR,POLYP FILM .27 UF 1000 VAC +8% −0% (460/575V model) 1 . . . . . . . . . . . . 14C3,4
192935Capacitor,Elctlt 2700 Uf 450 Vdc Can 2.52 Dia
. . . . . . . . .(200/230/460 Models)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14C3,4
217941Capacitor,Elctlt 1800 Uf 500 Vdc Can 2.52 Dia
. . . . . . . . .(460/575 Models)
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217942Spacer,Nylon Capacitor
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217040Nut,Nylon M12 Thread Capacitor Mounting
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pc7
221047 CIRCUIT CARD ASSY,RELINK (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Inverter Assy (Fig 8-1 Item 9) (Continued) Quantity 16
Pc2
221043 CIRCUIT CARD ASSY,INTERCONNECT (200/230/460V model) 1 . . . . . . . . . . . . . . . . . . . . 16Pc2
219900 CIRCUIT CARD ASSY,INTERCONNECT (460/575V model) 1 . . . . . . . . . . . . . . . . . . . . . . . .Plg2
168071Housing Plug Pins+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 185835Label,Warning Electric Shock/Exploding Parts
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 175140Bracket,Di−Dt
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178591Label,Connection Di/Dt
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 181197Gasket,Di−Dt Rubber
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20L3,4
175482Coil,Di/Dt
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 109056Core,Ferrite E 2.164 Lg X 1.094 High X .826 Wide
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Pm1,2
212936Kit,Transistor Igbt Module
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Rt2
213029Thermistor,Ntc 30K Ohm @ 25 Deg C 26In Lead 3P
1 . . . . . . . . . . . . . . . . . . . . . . . . 24 212776Heat Sink,Power Module
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 212753Heat Sink,Rect
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 175255Insulator,Rectifier
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 214537Cover,Access Fan Motor
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 181853Insulator,Screw
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29C2,R1,C5 175194
Resistor/Capacitor,
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Rt1
213028Thermistor,Ntc 30K Ohm @ 25 Deg C 26In Lead 2P
1 . . . . . . . . . . . . . . . . . . . . . . . . 31D1,2
201531Kit,Diode Power Module
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 199840Bus Bar,Diode
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 179276Bushing,Snap−In Nyl 1.000 Id X 1.375 Mtg Hole Cent
2 . . . . . . . . . . . . . . . . . . . . . . . . . . +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 54 Hardware is common and not available unless listed.
803 547-C
1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 Figure 8-4. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 8-4. Panel, Front w/Components (Fig 8-1 Item 23) Quantity 1 212837Handle,
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212845Bezel,Upper
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 212819Panel,Front
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 212825Enclosure,Circuit Card Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C8
200953Module,Filter .1Mf 500Vdc 10 Ckt
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 048282Rcpt W/Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C9,10
080894Capacitor,Cer Disc .01 Uf 1000 Vdc 20% Nylez
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 190363Rcpt W/Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S1
128756Switch,Tgl 3Pst 40A 600Vac Scr Term Wide Tgl
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 9Pc3
212979Circuit Card Assy,User Interface
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg18
115094Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg19
135560Housing Rcpt+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plg28
131055Housing Plug+Skts,(Service Kit)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 213936Label,Power/Mig Gun/Spoolgun
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 212847Bezel,Door
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218551Instruction,Flipchart
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215232Clip,Component .580H X .715W Adh Back
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213934Label,Nameplate Mm350
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213935Label,Nameplate Mm350P
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 212955Label,Controls User Interface
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 213134Knob,Encoder 1.670 Dia X .250 Id Push On W/Spring
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 210398Bushing,Snap−In
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pc6
220524Module, Tach (350 Model Only)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 55
803 549-B
Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 Figure 8-5. Panel, Rear w/Components Description Part No. Dia. Mkgs. Item No. Figure 8-5. Panel, Rear w/Components (Fig 8-1 Item 10) Quantity 1 212820Panel,Rear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 169654Bracket,Support Tank
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 200285Label,Warning Cylinder May Explode If Damaged
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 188441Chain,Weldless 2/0 X 31. Bright Zinc Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 220805Nut, 750−14 Nps 1.48Hex .41H Nyl
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Gs1
219062Valve, 34Vdc 1Way .750−14 Thd 1/8 Orf 100Psi
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 010467Conn,Clamp Cable 1.250
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 212772Cable,Power 10 Ft 6In 6Ga 4C (200/230/460V)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦213 380Plug,Str Grd 2P3W 50A 250Vac *6−50P
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 213018Cable,Power 10 Ft 6 In 10Ga 4C (460/575V)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213908Plate,Adapter Power Cord (575 Model Only)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 214654Label,Warning Electric Shock/Input Power
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1327 Page 56
803 548-B
Hardware is common and not available unless listed. Figure 8-6. Wire Drive Assembly See Table 8-1 Drive Roll & Wire Guide Kits. 1 17 19 20 24 18 20 19 2 16 15 6 26 9 10 11 12 13 27 3 33 34 23 22 26 27 28 29 30 31 32 28 27 26 21 19 20 25 14 37 28 35 36 27 26 5 7 8 9 10 11 12 13 4 Description Part No. Dia. Mkgs. 213137 Item No. Figure 8-6. Wire Drive Assembly Quantity 1 223541Kit,Mm350 Drive Motor W/ Instructions
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212844Insulator,Drive Housing 4 Roll
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 166337Housing,Adapter Gun/Feeder (Salable As 046621)
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 194521Insulator,Drive Assy
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 166071Lever,Mtg Pressure Gear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 166338Lever,Mtg Pressure Gear
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 079634Pin,Hinge
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 151828Pin,Cotter Hair .042 X .750
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 225718Fastener,Pinned
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 085244Washer,Cupped .328Idx .812Odx16Gax.125 Lip
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 196896Cup,Spring
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 196897Spring,Cprsn .695 Od X .095 Wire X 1.500
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 196895Knob,Tension
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 010224Pin,Spring Cs .187 X 1.000
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 079633Ftg,Hose Brs Barbed Nipple 3/16 Tbg
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 195640Screw,M 6−1.0X 16 Flathd−Phl Stl Pld
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 079240Screw,375−16X1.75 Hex Hd−Pln Stl Pld Full Thrd
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 601966Screw,375−16X1.25 Hex Hd−Pln Gr5 Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 602213Washer,Lock .380Idx0.691Odx.115T Stl Pld Split.375
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 602242Washer,Flat .375Idx0.875Odx.083T Stl Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 601872Nut, 375−16 .56Hex .34H Stl Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 108943Screw,250−20X1.50 Hexwhd.61D Gr5 Pld
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 221 654Washer,Shldr Insulating
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 57 Description Part No. Dia. Mkgs. 213137 Item No. Figure 8-6. Wire Drive Assembly (Continued) Quantity 24 089800
Nut, 250−20 .44Hex .22H Stl Pld .58D Flange Defor
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 602154Screw,250−20X .50 Hexwhd.50D Stl Pld Slffmg Tap−Rw
2 . . . . . . . . . . . . . . . . . . . . . . . 26 166072Spacer,Gear
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 172075Carrier,Drive Roll W/Components 24 Pitch
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 602009Screw,250−20X1.25 Soc Hd−Hex Gr8 Pln
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 173618Carrier,Drive Roll 10Mm Shaft
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 195802Washer,Flat .175Idx0.590Odx.040T Stl Pld
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 602241Washer,Flat .281Idx0.625Odx.065T Stl Pld Ansi.250
2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 174609Screw,M 4− .7X 12 Cheese Hd Blk Din 84
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 604538Washer,Flat .344Idx0.688Odx.065T Stl Pld Ansi.312
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 204585Knob,Fluted 1.75 In W/ .312−18 Stud 1.00 Lg
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 221912Guide,Wire Inlet Nylon .023 − .052
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 056207Guide,Wire Intermediate
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 189285Roll,Drive V Groove .035−.045 Wire
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Table 8-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 V-Knurled rolls for hard shelled cored wires. 4 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Wire Diameter Fraction Decimal Metric .023/.025 in .030 in .035 in .045 in .052 in 1/16 in .035 in .045 in .052 in 1/16 in .035 in .045 in .052 in 1/16 in .023/.025 in .030 in .035 in .045 in .052 in .062 in .035 in .045 in .052 in .062 in .035 in .045 in .052 in .062 in 0.6 mm 0.8 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm Kit No. 087 132 046 780 046 781 046 782 046 783 046 784 044 750 046 785 046 786 046 787 046 792 046 793 046 794 046 795 Drive Roll Part No. Type 087 130 053 695 053 700 053 697 053 698 053 699 072 000 053 701 053 702 053 706 132 958 132 957 132 956 132 955 V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved U-Grooved U-Grooved U-Grooved U-Grooved V-Knurled V-Knurled V-Knurled V-Knurled Wire Guide Inlet Intermediate 056 192 056 192 056 192 056 193 056 193 056 195 056 192 056 193 056 193 056 195 056 192 056 193 056 193 056 195 056 206 056 206 056 206 056 207 056 207 056 209 056 206 056 207 056 207 056 209 056 206 056 207 056 207 056 209 Ref. S-0025-D
OM-1327 Page 58 Item Number 1 2 3 4 5,7 Figure 8-7. Consumables Flowchart
OM-1327 Page 59 Description Part No. Item No. Figure 8-7. Consumables Flowchart Quantity Table 8-2. Nozzles 1 ♦176238 NOZZLE, spot flat (requires diffuser 209099, used with any . . . . . . . . . . . . . . heavy duty FasTip contact tip) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦176240 NOZZLE, spot inside corner (requires diffuser 209099, used with any . . . . . . . . . . . . . . heavy duty FasTip contact tip) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦176242 NOZZLE, spot outside corner (requires diffuser 209099, used with any . . . . . . . . . . . . . . heavy duty FasTip contact tip) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 610 NOZZLE, screw on brass 1/2 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 611 NOZZLE, screw on brass 3/4 in orifice straight 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 612 NOZZLE, screw on brass 3/4 in orifice straight heavy duty 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 613 NOZZLE, screw on brass 5/8 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 614 NOZZLE, screw on brass 5/8 in orifice heavy duty 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 615 NOZZLE, screw on copper 1/2 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 616 NOZZLE, screw on copper 3/4 in orifice 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦199 617 NOZZLE, screw on copper 3/4 in orifice heavy duty 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 198 855 NOZZLE, screw on copper 5/8 in orifice (standard on 300 & 400 . . . . . . . . . . . . . . . amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦207 313 NOZZLE, screw on copper 5/8 in orifice 15/16 OD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦209 033 NOZZLE, slip on copper 1/2 in orifice tapered (requires diffuser 209031 or . . . . . . . . . . . . . 209032 and insulator 209047, used with any tapered FasTip contact tip) 1 . . 1 ♦209 034 NOZZLE, slip on copper 3/8 in orifice tapered (requires diffuser 209031 or . . . . . . . . . . . . . 209032 and insulator 209047, used with any tapered FasTip contact tip) 1 . . 1 ♦209 035 NOZZLE, screw on copper 3/8 in orifice tapered (requires diffuser 206195, . . . . . . . . . . . . . 206196 or 210664, used with any tapered FasTip contact tip) 1 . . . . . . . . . . . 1 ♦209 036 NOZZLE, screw on copper 1/2 in orifice tapered (requires diffuser 206195, . . . . . . . . . . . . . 206196 or 210664, used with any tapered FasTip contact tip) 1 . . . . . . . . . . . Table 8-3. Heavy Duty FasTipContact Tips* 2 ♦206 184 .023 in (0.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 185 .030 in (0.8 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 186 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 187 .040 in (1.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 206 188 .045 in (1.2 mm) (standard on 300 & 400 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 189 .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 192 5/64 in (2.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦206 193 3/32 in (2.4 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-4. Extra Heavy Duty FasTipContact Tips* 2 ♦199 605 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 606 .040 in (1.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 851 .045 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 852 .052 in (1.3 mm) or 3/64 in (1.2 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 853 1/16 in (1.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦198 854 .068 in (1.7 mm) or 1/16 in (1.6 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 607 5/64 in (2.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 608 3/32 in (2.4 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 609 7/64−1/8 in (2.8 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 60 Description Part No. Item No. Figure 8-7. Consumables Flowchart (Continued) Quantity Table 8-5. Tapered FasTip Contact Tips* 2 ♦209024 .023 in (0.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209025 .030 in (0.8 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209026 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209027 .045 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209028 3/64 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209029 .052 in (1.3 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦209030 1/16 in (1.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-6. Value Multi−Turn Contact Tips* 2 ♦087 300 .023 in (0.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦071 825 .030 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦054 202 .035 in (0.9 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦054 201 .045 in (1.2 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 593 .3/64 in (1.2 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦044 006 .052 in (1.3 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦047 566 1/16 in (1.6 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦202 933 1/16 in (1.6 mm) aluminum wire 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦199 594 .068 in (1.7 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦047 565 5/64 in (2.0 mm) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-7. Gas Diffusers 3 ♦198 857 1/8 in tip recess − for extra heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦199 623 Flush tip − for extra heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦199 621 1/8 in tip recess − for value multi−turn contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦199 622 Flush tip − for value multi−turn contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦206 195 1/8 in tip recess − for heavy duty FasTip contact tips . . . . . . . . . . . . . (standard on all guns) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦210 664 1/4 in tip recess − for heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 206 196 Flush tip − for heavy duty FasTip contact tips 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦209 031 Slip on recessed diffuser (requires nozzle 209033 or 209034 . . . . . . . . . . . . . and insulator 209047, used with any tapered FasTip contact tip) 1 . . . . . . . . . . 3 ♦209 032 Slip on flush diffuser (requires nozzle 209033 or 209034 . . . . . . . . . . . . . and insulator 209047, used with any tapered FasTip contact tip) 1 . . . . . . . . . . 3 ♦209 099 Spot diffuser (requires spot nozzle 176238 or176240 or 176242) 1 . . . . . . . . . . . . . . . . . . . . . . . Table 8-8. Insulators 4 198 856 INSULATOR, Rubber 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 209 047 INSULATOR, Teflon (required when using diffuser 209031 or 209032 . . . . . . . . . . . . . . . with nozzle 209033 or 209034) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 202 292 COVER, nut 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-9. Liners 6 ♦202 889 LINER, monocoil .023−.030 wire x 16.5 ft round wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 202 890 LINER, monocoil .035−.045 wire x 16.5 ft round wound . . . . . . . . . . . . . . . (standard on 300 & 400 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 892 LINER, monocoil 1/16−.078 wire x 16.5 ft flat wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 893 LINER, monocoil 5/64−3/32 wire x 16.5 ft flat wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 894 LINER, monocoil 7/64−1/8 wire x 16.5 ft flat wound 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ♦202 895 LINER, monocoil 3/64−1/16 AL wire x 16.5 ft 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1327 Page 61 Description Part No. Item No. Figure 8-7. Consumables Flowchart (Continued) Quantity Table 8-10. Goosenecks 7 +199 625 GOOSENECK, jacketed 4.5 in/50deg wrench swivel . . . . . . . . . . . . . (standard on 300 & 400 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 +199 626 GOOSENECK, jacketed 6 in/50deg wrench swivel . . . . . . . . . . . . . (standard on 500 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 +199 627 GOOSENECK, jacketed 8 in/50deg wrench swivel . . . . . . . . . . . . . (standard on 600 amp models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 +♦213 450 GOOSENECK, jacketed 6.0” straight 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦Optional
+Includes nozzle insulator 198 856 and threaded nut cover 202 292. *All contact tips are packaged in bags of 25.Be Sure To Provide Model When Ordering Replacement Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model is required when ordering parts from your local distributor. Standard Consumables Chart Contact Tip 206 188 Nozzle 198 855 Diffuser 206 196 Liner 202 890 Gooseneck 199 625
OM-1327 Page 62
802 630-D
For consumable items 1 thru 7 see Figure 8-7. 16 8 15 14 13 12 11 9 10 8 5 7 6 4 3 2 1 Figure 8-8. 4012 Gun
OM-1327 Page 63 Description Part No. Item No. Figure 8-8. 4012 Gun Quantity 8 199 630 HANDLE KIT, 300 & 400 amp models (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 632 SCREW, M4 x 18 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 633
Nut, M4
4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 634 SCREW, M3 x 11 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 635Nut, M3
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 647 LABEL, gun handle Miller Roughneck 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 199 652 LABEL, back-end C-4012 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 199 637 SCREW, machine binding head 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 199 640 ADAPTER, Miller power pin (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 079 974 O-RING, Miller power pin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 079 878 HOUSING, plug and pins (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 531 CONN, circ cpc clamp str rlf size 11 .453 OD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ♦199 661 SWITCH, locking trigger 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 199 628 SWITCH, trigger (standard on all guns) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 199 629 SWITCH, contact pin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦199 662 HOOK, gun 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .♦Optional
Be Sure To Provide Model When Ordering Replacement Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model is required when ordering parts from your local distributor.
Warranty Questions? Call
1-800-4-A-Miller
for your local Miller distributor. miller_warr 2006−01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THISWarranty Is Expressly In Lieu Of All Other
Warranties, Express Or Implied, Including The
Warranties Of Merchantability And Fitness.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.Miller Products Are Intended For Purchase And
Use By Commercial/Industrial Users And Persons
Trained
And
Experienced
In
The
Use And
Maintenance Of Welding Equipment.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.To The Extent Permitted By Law, The Remedies
Provided Herein Are The Sole And Exclusive
Remedies. In No Event Shall Miller Be Liable For
Direct,
Indirect,
Special,
Incidental
Or
Consequential Damages (Including Loss Of
Profit), Whether Based On Contract, Tort Or Any
Other Legal Theory.
Any Express Warranty Not Provided Herein And
Any
Implied
Warranty,
Guaranty
Or
Representation As To Performance, And Any
Remedy For Breach Of Contract Tort Or Any
Other
Legal
Theory
Which,
But
For This
Provision, Might Arise By Implication, Operation
Of Law, Custom Of Trade Or Course Of Dealing,
Including
Any
Implied
Warranty
Of
Merchantability Or Fitness For Particular
Purpose, With Respect To Any And All Equipment
Furnished By Miller Is Excluded And Disclaimed
By Miller.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
Printed In Usa
© 2006 Miller Electric Mfg. Co.2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters − United Kingdom Phone: 44 (0) 1204-593493Fax: 44 (0) 1204-598066
www.MillerWelds.com Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to: For Service Owner’s Record File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. Contact your Distributor for:To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller