Miller Electric Welder S 74DX User Manual

OM-1500-9  
207 749K  
200605  
Processes  
MIG (GMAW) Welding  
Flux Cored (FCAW) Welding  
(Gas- And Self-Shielded)  
Description  
Wire Feeder  
S-74DX  
File: MIG (GMAW)  
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TABLE OF CONTENTS  
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 2 CONSIGNES DE SÉCURITÉ À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .  
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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OPTIONS AND ACCESSORIES  
WARRANTY  
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Declaration of Conformity for  
European Community (CE) Products  
This information is provided for units with CE certification (see rating label on unit).  
NOTE  
Manufacturer:  
European Contact:  
Miller Electric Mg. Co.  
1635 W. Spencer St.  
Appleton, WI 54914 USA  
Phone: (920) 734-9821  
Mr. Danilo Fedolfi,  
Managing Director  
ITW Welding Products Italy S.r.l.  
Via Privata Iseo 6/E  
20098 San Giuliano  
Milanese, Italy  
Phone: 39(02)98290-1  
Fax: 39(02)98290203  
European Contact Signature:  
Declares that the product:  
S-74DX  
conforms to the following Directives and Standards:  
Directives  
Low Voltage Directive: 73/23/EEC  
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC  
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC  
Standards  
Arc Welding Equipment Part 5: Wire Feeders. IEC 60974-5 Ed. 1  
Arc Welding Equipment Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002  
Arc Welding Equipment Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1  
Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1  
Insulation Coordination For Equipment Within Low-Voltage Systems −  
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1  
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.  
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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING  
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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.  
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.  
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Marks a special safety message.  
. Means “Note”; not safety related.  
1-2. Arc Welding Hazards  
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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.  
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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.  
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Only qualified persons should install, operate, maintain, and  
repair this unit.  
Do not touch electrode holders connected to two welding ma-  
chines at the same time since double open-circuit voltage will be  
present.  
During operation, keep everybody, especially children, away.  
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Use only well-maintained equipment. Repair or replace damaged  
parts at once. Maintain unit according to manual.  
ELECTRIC SHOCK can kill.  
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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.  
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  
groundedequipment is a hazard.  
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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.  
SIGNIFICANT DC VOLTAGE exists in inverter-type  
welding power sources after removal of input  
power.  
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Turn Off inverter, disconnect input power, and discharge input  
capacitors according to instructions in Maintenance Section  
before touching any parts.  
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FUMES AND GASES can be hazardous.  
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Additionalsafety 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  
semiautomaticDC 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!  
Welding produces fumes and gases. Breathing  
these fumes and gases can be hazardous to your  
health.  
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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.  
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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  
cadmiumplated 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.  
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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).  
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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  
groundedreceptacle outlet.  
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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.  
OM-1500-9 Page 1  
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ARC RAYS can burn eyes and skin.  
BUILDUP OF GAS can injure or kill.  
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Shut off shielding gas supply when not in use.  
Always ventilate confined spaces or use  
approved air-supplied respirator.  
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.  
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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).  
HOT PARTS can cause severe burns.  
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Wear approved safety glasses with side shields under your  
helmet.  
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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.  
Use protective screens or barriers to protect others from flash,  
glare and sparks; warn others not to watch the arc.  
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Wear protective clothing made from durable, flame-resistant mate-  
rial (leather, heavy cotton, or wool) and foot protection.  
WELDING can cause fire or explosion.  
MAGNETIC FIELDS can affect pacemakers.  
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  
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Pacemaker wearers keep away.  
Wearers should consult their doctor before  
going near arc welding, gouging, or spot  
welding operations.  
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.  
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If  
this is not possible, tightly cover them with approved covers.  
NOISE can damage hearing.  
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Do not weld where flying sparks can strike flammable material.  
Protect yourself and others from flying sparks and hot metal.  
Noise from some processes or equipment can  
damagehearing.  
Be alert that welding sparks and hot materials from welding can  
easily go through small cracks and openings to adjacent areas.  
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Wear approved ear protection if noise level is  
high.  
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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.  
CYLINDERS can explode if damaged.  
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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).  
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.  
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.  
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Protect compressed gas cylinders from excessive heat, mechani-  
cal shocks, physical damage, slag, open flames, sparks, and arcs.  
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Do not use welder to thaw frozen pipes.  
Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
Remove stick electrode from holder or cut off welding wire at  
contact tip when not in use.  
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Keep cylinders away from any welding or other electrical circuits.  
Never drape a welding torch over a gas cylinder.  
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Wear oil-free protective garments such as leather gloves, heavy  
shirt, cuffless trousers, high shoes, and a cap.  
Never allow a welding electrode to touch any cylinder.  
Never weld on a pressurized cylinder explosion will result.  
Remove any combustibles, such as a butane lighter or matches,  
from your person before doing any welding.  
Use only correct shielding gas cylinders, regulators, hoses, and fit-  
tings designed for the specific application; maintain them and  
associated parts in good condition.  
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B  
for hot work and have a fire watcher and extinguisher nearby.  
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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.  
FLYING METAL can injure eyes.  
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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.  
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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.  
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OM-1500-9 Page 2  
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1-3. Additional Symbols For Installation, Operation, And Maintenance  
FIRE OR EXPLOSION hazard.  
MOVING PARTS can cause injury.  
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Do not install or place unit on, over, or near  
combustiblesurfaces.  
Do not install unit near flammables.  
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Keep away from moving parts such as fans.  
Keep all doors, panels, covers, and guards  
closed and securely in place.  
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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.  
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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.  
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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.  
READ INSTRUCTIONS.  
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Read Owner’s Manual before using or servic-  
ing unit.  
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Use only genuine Miller/Hobart replacement  
parts.  
H.F. RADIATION can cause interference.  
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High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
Have only qualified persons familiar with  
electronic equipment perform this installation.  
OVERUSE can cause OVERHEATING  
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Allow cooling period; follow rated duty cycle.  
Reduce current or reduce duty cycle before  
starting to weld again.  
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Do not block or filter airflow to unit.  
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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  
equipmentat once.  
STATIC (ESD) can damage PC boards.  
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Have the installation regularly checked and maintained.  
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Put on grounded wrist strap BEFORE handling  
boards or parts.  
Use proper static-proof bags and boxes to  
store, move, or ship PC boards.  
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.  
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ARC WELDING can cause interference.  
MOVING PARTS can cause injury.  
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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  
electromagneticallycompatible.  
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Keep away from moving parts.  
Keep away from pinch points such as drive  
rolls.  
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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.  
WELDING WIRE can cause injury.  
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Do not press gun trigger until instructed to do  
so.  
Be sure this welding machine is installed and grounded  
according to this manual.  
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Do not point gun toward any part of the body,  
other people, or any metal when threading  
welding wire.  
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  
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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.)  
For Gasoline Engines:  
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Engine exhaust contains chemicals known to the State of  
California to cause cancer, birth defects, or other reproductive  
harm.  
For Diesel Engines:  
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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  
reproductiveharm. Wash hands after handling.  
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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-1500-9 Page 3  
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1-5. Principal Safety Standards  
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,  
from Global Engineering Documents (phone: 1-877-413-5184, website:  
www.global.ihs.com).  
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:  
8004636727 or in Toronto 4167474044, website: www.csain-  
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 100368002 (phone: 2126424900,  
website: www.ansi.org).  
Recommended Safe Practices for the Preparation for Weldingand 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).  
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 022699101 (phone:  
6177703000,website: www.nfpa.org).  
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-  
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA  
022699101(phone: 6177703000, 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 222024102 (phone: 7034120900, web-  
site: www.cganet.com).  
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  
3123532220,website: www.osha.gov).  
Code for Safety in Welding and Cutting, CSA Standard W117.2, from  
Canadian Standards Association, Standards Sales, 178 Rexdale  
1-6. EMF Information  
Considerations About Welding And The Effects Of Low Frequency  
Electric And Magnetic Fields  
1. Keep cables close together by twisting or taping them.  
2. Arrange cables to one side and away from the operator.  
3. Do not coil or drape cables around your body.  
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  
committees 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.  
4. Keep welding power source and cables as far away from opera-  
tor as practical.  
5. Connect work clamp to workpiece as close to the weld as possi-  
ble.  
About Pacemakers:  
Pacemaker wearers consult your doctor before welding or going near  
welding operations. If cleared by your doctor, then following the above  
procedures is recommended.  
To reduce magnetic fields in the workplace, use the following  
procedures:  
OM-1500-9 Page 4  
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SECTION 2 CONSIGNES DE SÉCURITÉ LIRE AVANT UTILISATION  
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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.  
Ce groupe de symboles signifie Avertissement ! Attention ! Risques  
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES  
CHAUDES. Consulter les symboles et les instructions afférentes  
ci-dessous concernant les mesures à prendre pour supprimer  
les dangers.  
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Indique un message de sécurité particulier  
. Signifie NOTE ; n’est pas relatif à la sécurité.  
2-2. Dangers relatifs au soudage à l’arc  
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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.  
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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.  
D
D
D
D
Y
Y
D
D
D
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  
D
D
D
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.  
D
D
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à  
une même borne de sortie de soudage.  
D
D
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.  
Il reste une TENSION DC NON NÉGLIGEABLE dans  
les sources de soudage onduleur quand on a coupé  
l’alimentation.  
D
D
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.  
D
D
D
LES FUMÉES ET LES GAZ peuvent  
être dangereux.  
Le soudage génère des fumées et des gaz. Leur  
inhalationpeut être dangereuse pour la santé.  
D
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.  
D
D
D
D
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.  
D
D
D
D
D
D
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer  
que le fil de terre du cordon d’alimentation est bien raccordé à la borne  
de terre du sectionneur ou que la fiche du cordon est raccordée à une  
prise correctement mise à la terre.  
En effectuant les raccordements d’entrée, fixer d’abord le conducteur  
de mise à la terre approprié et contre-vérifier les connexions.  
D
OM-1500-9Page 5  
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LES RAYONS D’ARC peuvent entraî-  
ner des brûlures aux yeux et à la peau.  
LES ACCUMULATIONS DE GAZ  
risquent de provoquer des blessures  
ou même la mort.  
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.  
D
Fermer l’alimentation du gaz protecteur en cas  
de non-utilisation.  
D
Veiller toujours à bien aérer les espaces confi-  
nés ou se servir d’un respirateur d’adduction  
d’air homologué.  
Des étincelles sont projetées pendant le soudage.  
D
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).  
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous vo-  
DES PIÈCES CHAUDES peuvent  
provoquer des brûlures graves.  
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.  
D
Ne pas toucher des parties chaudes à mains  
nues.  
D
Prévoir une période de refroidissement avant  
d’utiliser le pistolet ou la torche.  
D
D
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.  
LE SOUDAGE peut provoquer un  
incendie ou une explosion.  
Le soudage effectué sur des conteneurs fermés tels  
que des réservoirs, tambours ou des conduites peut  
provoquer leur éclatement. Des étincelles peuvent  
être projetées de l’arc de soudure. La projection  
LES CHAMPS MAGNÉTIQUES peuvent  
affecter les stimulateurs cardiaques.  
D
Porteurs de stimulateur cardiaque, rester  
à distance.  
d’étincelles,des pièces chaudes et des équipements chauds peuvent  
provoquer des incendies et des brûlures. Le contact accidentel de  
l’électrodeavec 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.  
D
Les porteurs d’un stimulateur cardiaque doi-  
vent d’abord consulter leur médecin avant de  
s’approcherdes opérations de soudage à l’arc,  
de gougeage ou de soudage par points.  
D
Déplacer toutes les substances inflammables à une distance de  
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi-  
gneusementavec des protections homologuées.  
LE BRUIT peut endommager l’ouïe.  
Le bruit des processus et des équipements peut  
affecter l’ouïe.  
D
D
D
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.  
D
Porter des protections approuvées pour les  
oreilles si le niveau sonore est trop élevé.  
LES BOUTEILLES peuvent exploser  
si elles sont endommagées.  
D
D
D
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.  
D
D
D
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-  
tionnaireou 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.  
D
D
D
D
D
D
Une électrode de soudage ne doit jamais entrer en contact avec  
une bouteille.  
D
D
Avant de souder, retirer toute substance combustible de ses poches  
D
D
Ne jamais souder une bouteille pressurisée risque d’explosion.  
telles qu’un allumeur au butane ou des allumettes.  
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-  
fisammentde 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.  
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.  
D
D
DES  
PARTICULES  
VOLANTES  
peuvent blesser les yeux.  
D
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.  
D
D
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran  
facial.  
OM-1500-9 Page 6  
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance  
Risque D’INCENDIE OU D’EXPLO-  
SION.  
DES ORGANES MOBILES peuvent  
provoquer des blessures.  
D
Ne pas placer l’appareil sur, au-dessus ou  
à proximité de surfaces inflammables.  
D
S’abstenirde toucher des organes mobiles tels  
que des ventilateurs.  
D
Ne pas installer l’appareil à proximité de  
produits inflammables.  
D
Maintenir fermés et verrouillés les portes,  
panneaux, recouvrements et dispositifs de  
protection.  
D
Ne pas surcharger l’installation électrique s’assurer que  
l’alimentationest correctement dimensionnée et protégée avant  
de mettre l’appareil en service.  
D
D
Seules des personnes qualifiées sont autorisées à enlever les  
portes, panneaux, recouvrements ou dispositifs de protection  
pour l’entretien.  
Remettreles portes, panneaux, recouvrements ou dispositifs de  
protection quand l’entretien est terminé et avant de rebrancher  
l’alimentation électrique.  
LA CHUTE DE L’APPAREIL peut  
blesser.  
LIRE LES INSTRUCTIONS.  
D
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.  
D
Lire le manuel d’utilisation avant d’utiliser ou  
d’intervenirsur l’appareil.  
D
D
Utiliser uniquement des pièces de rechange  
Miller/Hobart.  
D
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.  
LE  
RAYONNEMENT  
HAUTE  
FRÉQUENCE (HF) risque de provoquer  
des interférences.  
L’EMPLOI EXCESSIF peut SUR-  
CHAUFFER L’ÉQUIPEMENT.  
D
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.  
D
D
D
Prévoir une période de refroidissement ;  
respecter le cycle opératoire nominal.  
D
Demander seulement à des personnes qualifiées familiarisées  
avec des équipements électroniques de faire fonctionner l’instal-  
lation.  
L’utilisateurest 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.  
Maintenirsoigneusement 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.  
Réduire le courant ou le facteur de marche  
avant de poursuivre le soudage.  
Ne pas obstruer les passages d’air du poste.  
D
D
LES CHARGES ÉLECTROSTATIQUES  
peuvent endommager les circuits  
imprimés.  
D
D
D
Établir la connexion avec la barrette de terre  
avant de manipuler des cartes ou des pièces.  
D
Utiliser des pochettes et des boîtes antistati-  
ques pour stocker, déplacer ou expédier des  
cartes PC.  
LE SOUDAGE À L’ARC risque de  
provoquer des interférences.  
D
L’énergie électromagnétique peut gêner le  
fonctionnement d’appareils électroniques  
comme des ordinateurs et des robots.  
DES ORGANES MOBILES peuvent  
provoquer des blessures.  
D
Veiller à ce que tout l’équipement de la zone de  
D
Ne pas s’approcher des organes mobiles.  
soudage soit compatible électromagnétiquement.  
D
Ne pas s’approcher des points de coincement  
tels que des rouleaux de commande.  
D
Pour réduire la possibilité d’interférence, maintenir les câbles de  
soudage aussi courts que possible, les grouper, et les poser  
aussi bas que possible (ex. par terre).  
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-  
LES FILS DE SOUDAGE peuvent  
provoquer des blessures.  
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.  
D
Ne pas appuyer sur la gâchette avant d’en  
avoir reçu l’instruction.  
D
Ne pas diriger le pistolet vers soi, d’autres  
personnes ou toute pièce mécanique en enga-  
geant le fil de soudage.  
2-4. Proposition californienne 65 Avertissements  
Y
Les équipements de soudage et de coupage produisent des Pour les moteurs à essence :  
fumées et des gaz qui contiennent des produits chimiques dont  
Y
Les gaz d’échappement des moteurs contiennent des produits  
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)  
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 :  
Y
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.  
Y
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-1500-9Page 7  
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2-5. Principales normes de sécurité  
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone  
:
:
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou  
à
Toronto 416-747-4044, site Internet  
ternet : www.global.ihs.com).  
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).  
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).  
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).  
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).  
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  
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux régionaux−−le téléphone de la région 5, Chicago, est  
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220,site Internet : www.osha.gov).  
2-6. Information EMF  
Considérationssur le soudage et les effets de basse fréquence et des 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.  
champs magnétiques et électriques.  
2. Disposer les câbles d’un côté et à distance de l’opérateur.  
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  
3. Ne pas courber pas et ne pas entourer pas les câbles autour de  
certain souci à propos de tels champs. Cependant, après avoir examiné  
votre corps.  
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  
4. Garder le poste de soudage et les câbles le plus loin possible de  
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a  
vous.  
pas démontré que l’exposition aux champs magnétiques et champs élec-  
triques à haute fréquence représente un risque à la santé humaine ».  
5. Connecter la pince sur la pièce aussi près que possible de la sou-  
Toutefois, des études sont toujours en cours et les preuves continuent à  
dure.  
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.  
En ce qui concerne les stimulateurs cardiaques  
Les porteurs de stimulateur cardiaque doivent consulter leur médecin  
Pour réduire les champs magnétiques sur le poste de travail, appliquer avant de souder ou d’approcher des opérations de soudage. Si le méde-  
les procédures suivantes :  
cin approuve, il est recommandé de suivre les procédures précédentes.  
OM-1500-9 Page 8  
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SECTION 3 DEFINITIONS  
3-1. Warning Label Definitions  
A. Warning! Watch Out! There  
are possible hazards as  
shown by the symbols.  
B. Drive rolls can injure fingers.  
A
B
C
C. Welding wire and drive parts  
are at welding voltage during  
operation keep hands and  
metal objects clear.  
1
Electric shock can kill.  
1.1 Wear dry insulating gloves.  
Do not touch electrode with  
bare hand. Do not wear wet or  
damaged gloves.  
1.2 Protect yourself from electric  
shock by insulating yourself  
from work and ground.  
1
2
1.1  
2.1  
3.1  
4.1  
1.2  
1.3  
1.3 Disconnect input plug or  
power before working on  
machine.  
2
Breathing welding fumes can  
be hazardous to your health.  
2.2  
2.3  
2.1 Keep your head out of the  
fumes.  
2.2 Use forced ventilation or local  
exhaust to remove the fumes.  
2.3 Use ventilating fan to remove  
fumes.  
3
4
5
3.2  
3.3  
3
Welding sparks can cause  
explosion or fire.  
3.1 Keep flammables away from  
welding. Don’t weld near  
flammables.  
3.2 Welding sparks can cause  
fires. Have a fire extinguisher  
nearby and have a watch  
person ready to use it.  
+ + +  
3.3 Do not weld on drums or any  
closed containers.  
4
Arc rays can burn eyes and  
injure skin.  
6
4.1 Wear hat and safety glasses.  
Use ear protection and button  
shirt collar. Use welding  
helmet with correct shade of  
filter. Wear complete body  
protection.  
+
S-178 936  
5
Become trained and read the  
instructions before working on  
the machine or welding.  
6
Do not remove or paint over  
(cover) the label.  
OM-1500-9 Page 9  
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3-2. Rating Label For CE Products  
For label location  
S/N:  
U1  
I =  
1
50/60 Hz  
IP 21  
24 V  
10.0A  
1
=
U2  
=
I =  
750 A  
2
100 V  
X 100 %  
ST-178 794-A  
3-3. Symbols And Definitions  
Some symbols are found only on CE products.  
Note  
Amperes  
Volts  
AlternatingCurrent  
Program  
Duty Cycle  
A
IP  
V
Hz  
X
Degree Of  
Protection  
Hertz  
Wire Feed  
Jog  
Output  
Trigger  
Line Connection  
Set Up  
Sequence  
Trigger Hold On  
Trigger Hold Off  
Crater  
Purge  
Time  
Press To Set  
Preflow Time  
Start  
Postflow Time  
Rated Current  
Read Instructions  
Load Voltage  
Increase  
Primary Current  
Dual Schedule  
I1  
I2  
U2  
A
B
Primary Voltage  
U1  
OM-1500-9 Page 10  
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SECTION 4 INTRODUCTION  
4-1. Specifications  
Type of  
Input Power  
Welding Power  
Source Type  
Wire Diameter  
Range  
Welding  
IP  
Overall  
Dimensions  
Wire Feed Speed Range  
Weight  
Circuit Rating Rating  
24 Volts AC  
Single-Phase  
10 Amperes  
50/60 Hertz  
Constant Voltage  
(CV)  
DC With 14-Pin  
And Contactor  
Control  
Standard: 50 To 780 ipm  
(1.2 To 19.8 mpm)  
.023 To 1/8 in  
100 Volts,  
750 Amperes,  
100% Duty  
Cycle  
IP 21  
Length: 27 in  
(686 mm)  
45 lb  
(20.4 kg)  
(0.6 To 3.2 mm)  
Width: 12-1/2 in  
(318 mm)  
Optional High Speed: 92 To  
1435 ipm (2.3 To 36.4 mpm)  
Max Spool  
Weight: 60 lb  
(27 kg)  
Height: 14 in  
(356 mm)  
Optional Low Speed: 19 to  
300 ipm (0.4 to 7.6 mpm)  
SECTION 5 INSTALLATION  
5-1. Site Selection  
Y
Y
Do not put feeder where  
welding wire hits cylinder.  
Do not move or operate  
equipmentwhen it could tip.  
3
1
2
Wire Feeder  
Rubber Feet  
4
Choose slot that allows all rubber  
feet to sit securely on top of welding  
power source.  
1
3
4
Wire Spool/Reel  
5
Gas Cylinder w/Hose And  
Regulator (Customer  
Supplied)  
2
. Shielding gas pressure not to  
exceed 100 PSI (689 kPa).  
5
6
Welding Power Source  
Running Gear  
. Factory voltage settings are V-  
Min 10 and V-Max 38. If you are  
using a power source with a dif-  
ferent voltage range, see Sec-  
tion 5-8 for V-Min And V-Max  
adjustments.  
6
Ref. ST-152 468-A / ST-152 467-C  
OM-1500-9 Page 11  
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5-2. Rear Panel Connections And Rotating Drive Assembly  
1
2
14-Pin Control Cable 10 ft  
(3.0 m)  
Shielding Gas Valve Fitting  
Requires fitting with 5/8-18 right-  
hand threads. Connect customer-  
supplied gas hose.  
. Shielding gas pressure not to  
exceed 100 PSI (689 kPa).  
3
4
5
6
Weld Cable Terminal  
Weld Cable  
Drive Assembly  
Drive Assembly Rotation  
Knob  
7
7
Rating Label Location  
To rotate the drive assembly, loos-  
en drive assembly rotation knob,  
rotate drive assembly, and tighten  
knob.  
2
1
3
4
5
6
Tools Needed:  
9/16, 5/8 in  
3/16 in  
802 824-A / 802 825-A  
OM-1500-9 Page 12  
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5-3. 14-Pin Plug Information  
Pin*  
Pin Information  
A
B
G
C
D
E
H
F
24 volts ac with respect to socket G.  
Contact closure to A completes 24 volts ac contactor control circuit.  
Circuit common for 24 volts ac circuit.  
J
A
K
I
B
C
L
H
N
+10 volts dc input from power source to wire feeder with respect to socket D.  
Remote control circuit common.  
M
E
G
D
F
0 to +10 volts dc output signal from wire feeder to power source with respect to socket D.  
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.  
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.  
*The remaining pins are not used.  
5-4. Gun Recommendation Table  
Process  
Gun  
GMAW Hard or Cored Wires  
Roughneck C-Series Guns: 300,  
400, 500, And 600 Amp.  
FCAW Self-Shielding Wires  
FC-1260 Or FC-1150  
5-5. Wire Type, Size, And Feed Speed Capability Table  
Motor Speed  
Standard  
Wire Type  
Wire Size  
Feed Speed Capability  
All  
All  
All  
.023 To 5/64 in (0.6 To 2 mm)  
3/32 To 7/64 in (2.4 To 2.8 mm)  
1/8 in (3.2 mm)  
50 To 780 ipm (1.2 To 19.8 mpm)  
50 To 700 ipm (1.2 To 17.8 mpm)  
50 To 300 ipm (1.2 To 7.6 mpm)  
Standard  
Standard  
Optional High  
Speed  
All  
All  
.023 To 5/64 in (0.6 To 2 mm)  
.023 To 1/8 in (0.6 To 3.2 mm)  
92 To 1435 ipm (2.3 To 36.4 mpm)  
19 To 300 ipm (0.4 To 7.6 mpm)  
Optional Low  
Speed  
OM-1500-9 Page 13  
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5-6. Installing And Threading Welding Wire  
Install wire guides and  
anti-wear guide.  
Install wire spool. Adjust tension nut so  
wire is taut when wire feed stops.  
Install drive rolls.  
Pressure  
Indicator  
Scale  
Pressure  
Adjust  
Rear  
Rolls  
Pressure  
Adjust  
Front  
Rolls  
No Wire Slip  
Wire Slips  
NONCONDUCTIVE  
SURFACE  
NONCONDUCTIVE  
SURFACE  
Drive Rolls  
Gun Cable  
Tools Needed:  
3/16, 5/64 in  
15/16, 3/8 in  
End Of Liner  
. Be sure that outlet cable has proper size . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle  
liner for the welding wire size. When  
installing gun, position liner  
extending from outlet wire guide as  
close as possible to drive rolls without  
touching.  
steel wire, reduce drive roll pressure on  
the rear roll to half that of the front rolls.  
about 2 in (51 mm) from nonconductive  
surface and press gun trigger to feed wire  
against surface. Tighten knob so wire  
does not slip. Do not overtighten. If con-  
tact tip is completely blocked, wire should  
slip at the feeder (see pressure adjust-  
ment above).Cut wire off. Close cover.  
Install gun. Lay gun cable out straight. Cut off  
end of wire. Push wire through guides up to  
drive rolls; continue to hold wire. Press Jog  
button to feed wire out gun.  
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A  
OM-1500-9 Page 14  
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5-7. Setting Internal DIP Switches  
1
2
DIP Switch S1  
DIP Switch S4 (Not For Customer Use)  
DIP switch S1 allows the user to make a num-  
ber of choices affecting unit operation.  
w Defining Motor Speed (S1-7 & 8)  
Switches 7 and 8 allow the user to define  
whether the motor in use is standard speed  
(50-780 inches per minute), or high speed  
(92-1435 inches per minute), or low speed  
(19-300 inches per minute).  
. When DIP switch positions are changed, the  
unit must be turned Off and then On again in  
order for the new settings to be active. DIP  
switches are only read on power up.  
1
O
N
1
2
3
4
5
6
7
8
. In the DIP switch S1 illustrations,  
the elevated slider on each switch  
is shown in white. For example,  
the switches above are all in the  
Off position.  
2
802 808  
Position Settings And Results For DIP Switch S1  
7
7
8
8
7
8
7 Off, 8 Off = Standard  
speed motor (50-780 inch-  
es per minute, or 1.2-19.8  
meters per minute)  
7 On, 8 On = Low Speed  
Motor (19-300 inches per  
minute, or 0.4-7.6 meters per  
minute).  
7 Off, 8 On = High speed  
motor (92-1435 inches per  
minute, or 2.3-36.4 meters  
per minute)  
OM-1500-9 Page 15  
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5-8. Power Source Selection Menu  
1
2
Upper Display  
Lower Display  
Non-CE Model Shown  
1
. When the feeder is turned on,  
the Power Source Selection  
Menu allows the operator to se-  
lect a default power source.  
Selecting  
a
default power  
source, automatically sets the  
correct Vmin and Vmax set-  
tings for adjusting the output  
voltage of the power source.  
Program  
Volts  
Time (sec)  
First Time Feeder Is Turned On  
The feeder automatically goes into  
the Power Source Selection Menu.  
The feeder displays “dELT” on the  
Upper Display and “452” on the  
Lower Display, meaning that a Del-  
taweld 452 is the default power  
source, and has a voltage range of  
10V as Vmin and 38V as Vmax.  
Wire Speed  
Amps  
2
Start  
Trigger Hold  
Crater  
Pre/Postflow  
Dual Schedule  
At power up, the operator has three  
seconds to select a default power  
source from the list shown on the  
display. Operator may scroll  
throughthe list of power sources by  
using the Adjust control. After se-  
lecting a power source the operator  
has three seconds to change to a  
different power source or begin  
welding. After making a power  
source selection, the operator may  
press the Program Button to avoid  
having to wait the three seconds.  
When turning off the feeder, the de-  
fault power source will be retained.  
Sequence  
Adjust  
Setup  
Upper Display  
Voltage Range  
* * Power Source  
Lower Display  
Deltaweld 452  
Deltaweld 302  
Deltaweld 652  
Dimension 302  
Dimension 452  
Dimension 652  
Dimension 1000  
XMT 304  
dELT  
dELT  
dELT  
dIM  
452  
302  
652  
302  
452  
652  
1000  
304  
456  
MP  
Vmin =10  
Vmax =38  
Vmax =32  
Vmax =44  
Vmax =32  
Vmax =38  
Vmax =65  
Vmax =60  
Vmax =35  
Vmax =38  
Vmax =35  
Vmax =38  
Vmax =38  
Vmax =38  
Vmax =44  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =10  
Vmin =25  
If voltage settings have already  
been set with the Vmin and Vmax in  
the Auxiliary Menu, selecting a de-  
fault power source with the Power  
Source Selection Menu overrides  
the Vmin and Vmax voltage set-  
tings.  
dIM  
dIM  
dIM  
XMT  
XMT  
I354  
I456  
I456  
PHX  
SUM  
XMT 456  
Next Time Feeder Is Turned On  
Invision 354MP  
Invision 456MP  
Invision 456P  
PHOENIX 456  
SUMMITARC 1000  
The feeder will display the last se-  
lected default power source. The  
operator has three seconds to se-  
lect another power source, or press  
the Program Button to exit the Pow-  
er Source Selection Menu.  
MP  
P
456  
1000  
Disabling The Power Source  
Selection Menu  
Once the default power source has  
been selected the Power Source  
Selection Menu may be disabled  
using the Auxiliary Menus. See  
Section 6-10.  
** For any power sources not listed, pick a matching voltage range, or see Sec 5-10 to  
set Vmin and Vmax.  
OM-1500-9 Page 16  
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SECTION 6 OPERATION  
6-1. Operational Terms  
The following is a list of terms and their definitions as they apply to this wire feeder:  
General Terms:  
Cold Wire Jog  
Sequence  
Feeding wire without contactor or gas valve being energized.  
A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.  
A group of sequences that make up a weld cycle.  
Weld Program  
6-2. Power Switch  
1
1
Power Switch  
802 809-A  
6-3. Program Push Button  
1
Program Display  
The number of the active program  
is displayed.  
Non-CE Models  
CE Models  
2
Program Push Button  
Press button to activate program  
select feature. To change the pro-  
gram number, press the Program  
push button and rotate the Adjust  
control.  
1
1
2
3
Program Push Button LED  
The LED lights to indicate the Pro-  
gram push button is active.  
Program  
3
3
2
OM-1500-9 Page 17  
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6-4. Front Panel Controls  
Nameplate For Non-CE Models  
See  
Section  
See  
Section  
Program  
See  
Section  
Volts  
Time (sec)  
Wire Speed  
Amps  
Start  
Dual Schedule  
Trigger Hold  
Crater  
Pre/Postflow  
Sequence  
Adjust  
Setup  
See  
Section  
See  
Section  
See  
Section  
Nameplate For CE Models  
See  
Section  
See  
Section  
See  
Section  
See  
Section  
See  
Section  
See  
Section  
OM-1500-9 Page 18  
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6-5. Upper Display  
. To set the correct voltage range for a particular power  
source, see Section 5-8 for power source selection menu,  
or Section 6-10 for V-Min And V-Max adjustments.  
Non-CE Models  
3
1
4
2
Volts  
Time (sec)  
5
CE Models  
3
1
4
2
5
1
Upper Display  
nates to indicate that information displayed  
can be changed by the Adjust control.  
play push button repeatedly until welding  
time is the active parameter in the upper  
display. At idle, the upper display toggles  
between showing weld voltage or weld  
time, with subsequent presses of the up-  
per display push button.  
The upper display shows voltage or time.  
The unit displays both preset and actual arc  
voltage. When the unit is in a welding state,  
actual arc voltage is displayed. The upper  
display shows welding sequence time when  
the Time LED is illuminated.  
4
5
Volts LED  
Time LED  
The LEDs below the display illuminate to in-  
dicate which value is being shown.  
The unit defaults to displaying welding  
voltage when a welding sequence display  
mode is first entered.  
At any time while welding, the unit permits  
the adjustment of the weld sequence voltage  
and overrides the display of actual arc volt-  
age.  
2
Upper Display Push Button  
Press and hold button to adjust or display  
weld time. Release button to display voltage.  
If the weld sequence has a time set (as in  
spot time), after the weld program is com-  
pleted, ERR TRG 1 will be displayed to in-  
dicate the weld program is complete. Re-  
lease trigger to clear error.  
If the unit is displaying a welding sequence  
that can be timed, the welding time display  
mode is entered by pressing the upper dis-  
3
Upper Display Push Button LED  
The upper display push button LED illumi-  
OM-1500-9 Page 19  
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6-6. Lower Display  
3
2
1
Non-CE Models  
4
Wire Speed  
Amps  
5
3
1
4
2
CE Models  
5
1
Lower Display  
to indicate that information displayed can be  
changed by the Adjust control.  
just control is activated while welding, the  
unit displays and permits adjustment of the  
weld sequence wire feed speed regardless  
of the active welding sequence.  
The lower display shows wire speed or  
amperage.The unit displays and adjusts only  
preset wire speed at idle. When the unit is in a  
welding state, actual wire speed is displayed  
for the active welding sequence.  
4
5
Wire Speed LED  
Amps LED  
When the unit is displaying amperage, the  
Amps LED illuminates. Amperage is only  
displayed if the unit is in a welding state and  
the amperage is above a minimum value of  
25 Amps.  
The LEDs below the display illuminate to indi-  
cate which value is being shown.  
2
Lower Display Push Button  
If the unit is in a welding state that does not  
involve feeding wire, the unit displays the  
weld sequence wire speed. At any time dur-  
ing welding, the weld sequence wire speed The display will read dashes for amperage  
can be adjusted and overrides the preset  
wire speed display. In other words, if the Ad-  
Press button to choose between wire speed or  
amperagefunctions.  
3
Lower Display Push Button LED  
readings below the amperage threshold,  
prior to arc initiation.  
The lower display push button LED illuminates  
6-7. Setup Push Button  
3
3
4
Trigger Hold  
4
2
Dual Schedule  
2
1
1
Setup  
Non-CE Models  
CE Models  
1
Setup Push Button  
the trigger hold status or press the lower dis- When the Setup button is pressed a second  
play push button. If trigger hold is turned On,  
the trigger hold LED illuminates and stays  
On.  
time, the dual schedule LED flashes. In this  
mode the upper display indicates DUAL and  
the lower display indicates dual schedule  
status On/Off. Use the Adjust control to  
change the dual schedule status if desired.  
Press button to choose between trigger hold  
or dual schedule functions.  
2
3
4
When the Setup button is pressed, the Set-  
up push button LED flashes and the Trigger  
Hold LED flashes.  
Setup Push Button LED  
Trigger Hold LED  
Dual Schedule LED  
When trigger hold is On, the user must  
press and hold the trigger for a predefined  
amountof time (the trigger hold delay time−  
see Section 6-10), then release it for the trig-  
ger hold function to be active. To shut off the  
weld when trigger hold is On, the user must  
press and release the trigger.  
Pressing the Setup button again exits the  
Setup mode. The dual schedule LED stops  
flashingto indicate the dual schedule status  
is Off.  
The flashing LED indicates that the unit is in  
the trigger hold display mode. In this mode  
the upper display indicates HOLD and the  
While in the Setup mode, the active program  
can be adjusted without deactivating the  
trigger hold Setup mode operation. If the  
trigger is activated, Setup mode(s) is termi-  
nated.  
If a weld time is programmed, trigger hold is  
disabled.  
lower display indicates the trigger hold sta- Trigger hold and dual schedule cannot be  
tus On/Off. Use the Adjust control to change  
used concurrently.  
OM-1500-9 Page 20  
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6-8. Adjust Control  
1
Adjust Control  
The Adjust control is used to  
change various sequence parame-  
ters, and to select various se-  
quences. Refer to the section for  
the function in question for informa-  
tion related to using the Adjust con-  
trol.  
1
1
Adjust  
Non-CE Models  
CE Models  
6-9. Sequence Push Button  
1
2
3
Sequence Push Button  
Sequence Push Button LED  
Welding Sequence LEDs  
Start  
3
3
Crater  
Pre/Postflow  
Weld  
2
1
Start  
Time  
Crater  
Time  
2
Time  
Preflow  
Time  
1
Postflow  
Time  
Sequence  
Welding Sequence Diagram  
Non-CE Models  
CE Models  
the weld display mode is activated.  
When the Sequence push button is pressed  
a third time, the Preflow/Postflow sequence  
LED flashes. The Sequence push button  
LED remains flashing. In the Preflow display  
mode the upper display shows the preflow  
time and the lower display indicates the ab-  
breviation PRE, to inform the operator that  
preflow time is displayed. If the upper dis-  
play push button is pressed, the Adjust con-  
trol can be used to adjust preflow.  
. For more information on Setting  
If zero time is programmed for a timed se-  
quence except for Weld, that sequence will  
be skipped.  
The Sequence push button allows the  
selection of welding sequences. Five weld-  
ing sequences are available. The default  
sequence is the Weld sequence. The Weld  
sequence is active on power up. Three  
welding sequence LEDs are located above  
the Sequence push button: Start, Crater,  
and Preflow/Postflow. The applicable LED  
illuminates to indicate which welding se-  
quence is active.  
In the weld sequence display mode the Se-  
quence push button LED is Off. When the  
Sequence push button is pressed, the Se-  
quence push button flashes and the Start  
LEDs flash. In this condition, the unit is in the  
Start sequence display mode, and Start se-  
quence parameters are shown in the dis-  
plays.  
If the lower display push button is pressed, the  
Adjust control can be used to select between  
preflow PRE and postflow POST. When  
POST is selected, the upper display can be  
used to specify postflow time.  
When the Sequence push button is pressed  
a second time, the Crater sequence LED  
flashes. The Sequence push button LED re-  
mains flashing. In this condition, the unit is  
in the Crater sequence display mode, and When the Sequence push button is pressed  
Crater sequence parameters are shown in  
the displays.  
The LED illuminates to indicate that a weld-  
ing sequence display mode other than Weld  
is activate. Welding sequences other than  
Weld must be set prior to initiating the arc.  
When the unit enters a welding state, all se-  
quence display modes are terminated and  
a fourth time, the unit returns to the welding  
sequence display mode.  
OM-1500-9 Page 21  
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6-10. Auxiliary Menus  
1
2
3
4
5
6
7
8
9
Program Display  
Program Push Button  
Sequence Push Button  
Upper Display  
Non-CE Models  
4
Upper Display Push Button  
Lower Display  
Lower Display Push Button  
Adjust Control  
5
7
1
Setup Push Button  
2
Program  
Volts  
Time (sec)  
Wire Speed  
Amps  
6
Start  
Trigger Hold  
Crater  
Pre/Postflow  
Dual Schedule  
9
3
Sequence  
Adjust  
Setup  
8
CE Models  
4
5
1
2
7
6
9
3
8
OM-1500-9 Page 22  
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6-10 Auxiliary Menus (Continued)  
Reset To Factory Settings  
Arc Time  
hold delay time of 2.0 seconds is defined,  
and the operator held the trigger in for more  
than 6.0 seconds, the trigger hold function  
would not be in effect and the wire feeder  
would stop when the trigger is released.  
A reset menu is displayed if the following four  
push buttons are pressed simultaneously:  
Program, Sequence, upper display, and Set-  
up. The upper display indicates “WIPE” . The  
lower display indicates “OFF”. The lower push  
button is active indicating that the Adjust con-  
trol can be used to change the unit to “WIPE  
ON”. When “WIPE ON” is set, if the original  
four push buttons are simultaneously pressed  
a second time, the unit will reset all settings to  
factory default except the arc time and arc  
cycle counts. If a reset is not desired, set the  
display to “WIPE OFF” and simultaneously  
press the Program, Sequence, upper display,  
and Setup push buttons to exit the reset menu.  
If the Setup push button is pressed, the unit  
displays arc time in hours.  
Arc time is indicated by the Program display  
showing “HR”. Arc time is shown in the lower  
display.  
When the Setup push button is pressed  
again, the menu repeats to the first menu  
selection of run-in wire speed selection.  
Cycles  
Trigger Program Select  
If the Setup push button is pressed, the unit  
displays the number of cycles.  
If the Setup push button is pressed, the unit  
allows Trigger Program Select to be dis-  
abled or enabled.  
Arc cycles are indicated by the Program dis-  
play showing “CL”. The arc cycle count is  
shown in the lower display.  
The upper display shows “TSEL”. Lower dis-  
play shows “On” or “Off”. The Adjust Control is  
used to select either “On” or “Off”.  
Run-In  
If the Setup button is pressed, the unit allows  
setting the run-in modes. The run-in modes  
are program specific. Each program may be  
set to its own run-in mode.  
Auxiliary Menu  
Trigger Program Select allows the operator to  
select programs by clicking the trigger (pulling  
and releasing the trigger in a maximum of 0.2  
seconds). The feeder will switch between any  
programsthat have a minimum of 0.2 seconds  
of preflow time set in the weld sequence. If pro-  
grams 1 and 3 have a minimum of 0.2 seconds  
of preflow time, clicking the trigger will toggle  
between programs 1 and 3. If programs 1, 2,  
and 4 have a minimum of 0.2 seconds of pre-  
flow time, clicking the trigger will switch from 1  
to 2 to 4 to 1 to 2. Any combination of programs  
may be used. Trigger Program Select cannot  
be used while welding or with Dual Schedule.  
An auxiliary menu is provided if both the Se-  
quence and Setup push buttons are pressed  
simultaneously. The Setup push button and  
sequence push button LEDS flash when the  
auxiliary menu is displayed.  
The upper display indicates “RUNI”. The  
lower display indicates “AUTO”, meaning the  
factory set automatic run-in speed is se-  
lected.  
Pushing the Setup push button will step  
through the menu. Pushing the sequence  
push button will step through the menu in re-  
verse.  
Pressing the lower display button allows a  
manual setting the run-in wire speed. Speed  
may be adjusted from 10% to 100% of weld  
wire speed.  
. The auxiliary menu may be exited at any  
time by pressing both the Sequence push  
button and the Setup push buttons simul-  
taneously.  
Pressing the lower display button allows dis-  
abling of the run-in feature. When the lower  
display indicates “OFF” run-in is disabled.  
Process Select  
V-Min And V-Max  
Process selection indicated by ”PROS” in the  
upper display is set to either ”VOLT” or ”TRIM”  
in the lower display. Each program can be se-  
lected be be a MIG program indicated by  
”VOLT” or a pulsing program indicated by  
”TRIM”.  
Burnback  
If the Setup push button is pressed, the unit  
allows the setting of the manual override  
power source min and max voltage preset  
range. The minimum voltage is displayed in  
the upper display and the lower display indi-  
cates “VMIN”. When the Setup push button  
is pressed the unit displays the maximum  
voltage setting of the welding power source.  
The maximum voltage is displayed in the up-  
per display and the lower display indicates  
“VMAX”.  
If the Setup push button is pressed, the unit  
allows burnback time to be set.  
Burnback time and voltage can be specified  
when the lower display indicates “BURN” and  
the upper display indicates the burnback time  
or voltage. The Adjust control is used to set the  
desired burnback time or voltage. Burnback  
settings, like run-in settings, are program spe-  
cific. The active program is displayed in the  
Program display and can be adjusted (see  
Section 6-3).  
Range Locks  
Range locks are indicated by “LOCK” in the  
upper display for wire speed or “LOCK” in the  
lower display for voltage range. In a MIG pro-  
gram, the voltage range lock ranges from 0 to  
10 volts. In a pulse program, the trim range  
lock ranges from 0 to 100. The wire feed speed  
range lock ranges from 0 to 250 ipm. Locks are  
program dependent and wire speed is inde-  
pendentfrom voltage or trim.  
In both cases, the Adjust control is used to  
specify the minimum and maximum voltage  
settings of the welding power source. The set-  
tings correspond to arc voltage obtained at  
minimumcommand and arc voltage obtained  
at maximum command.  
Trigger Hold Setup  
If the Setup push button is pressed, the unit  
allows trigger hold delay time to be set.  
Wire Feed Speed Units  
Trigger hold delay time is indicated by ”HOLD”  
in the lower display and the hold delay time in  
the upper display. The adjust control can be  
used to specify a new delay time for trigger  
hold. Trigger hold delay time is the minimum  
amountof time the trigger must be held for trig-  
ger hold to work when the trigger is released  
(the trigger hold function must be on). For ex-  
ample, if a trigger hold delay time of 2.0 sec-  
onds is defined, the operator must hold the  
trigger for at least 2 seconds before releasing  
This method of setting “VMIN” and “VMAX”  
may be used if the power source being used  
is not listed in the Power Source Selection  
Menu.  
Wire feed speed setting indicated by “WFS” in  
the upper display is set to “IPM” inchesper−  
minute or ”MPM” metersperminute. This  
setting is independent of the program se-  
lected.  
. If a default power source has already been  
selected with the Power Source Selection  
menu, setting “VMIN” and “VMAX” will  
override the default power source set-  
tings.  
OPT1  
If the Setup push button is pressed, the unit  
allows OPT1 to be disabled or enabled.  
it in order for the trigger hold function to work. The upper display shows “OPT1”. Lower dis-  
Once the trigger hold function is in effect, the play shows “On” or “Off”. The Adjust Control is  
wire feeder will stay On until the trigger is  
pressed and released again.  
. The power source selection menu must  
be set to “OFF” when overriding the de-  
fault “VMIN” or “VMAX” settings.  
used to select either “On” or “Off”.  
“OPT1” is used by the Water Flow Shutdown  
Power Source Selection Menu  
There is an additional function built in called Option to stop the weld sequence if water flow  
”maximum trigger hold time” which is the  
maximum length of time the trigger can be set of contacts between pins 1 and 2 of RC26  
held and the trigger hold function still work on Interface Board (PC20) will allow feeder to  
to a water cooled gun is interrupted. A closed  
If the Setup push button is pressed, the unit  
allows the Power Source Selection menu to  
be disabled or enabled.  
when the trigger is released (the trigger hold operate normally. Opening the contacts will  
function must be on). The maximum trigger stop the weld sequence and display “ERR” in  
hold time is set at 4.0 seconds after the trig- the upper display and “OPT1” in the lower dis-  
ger hold delay time. For example, if a trigger play.  
The upper display shows “PSS”. Lower dis-  
play shows “On” or “Off”. The Adjust Control is  
used to select either “On” or “Off”.  
OM-1500-9 Page 23  
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6-10 Auxiliary Menus (Continued)  
OPT2  
hold the last weld information for 5 seconds  
must be selected to gain access to the auxilia-  
ry menu. A failed attempt return the user to the  
weld screen and a counter is incremented. A  
counter in the program display shows the  
number of incorrect attempts. The user has  
five attempts to enter the correct password  
code before being locked out of the auxiliary  
menu, indicated by “LOCK” in the lower dis-  
play . The power may be cycled to continue  
welding but the user will remained locked out  
of the auxiliary menu. Pressing the Program,  
Sequence, upper display, and Setup push  
buttons simultaneously, the counter can be re-  
set in the weld screen. Resetting the counter  
is indicated by “CODE” in the upper display  
and “RSET” in the lower display. Pressing the  
Program, Sequence, upper display, and Set−  
up push buttons simultaneously again will al-  
low the user to reset the unit to the factory de-  
faults, indicated by “WIPE” in the upper dis-  
play. Resetting the unit will also turn off the  
password code feature.  
following weld termination. If any front panel  
push button is pressed, or if the Adjust control  
is activated, the display hold feature is termi-  
nated.  
If the Setup push button is pressed, the unit  
allows OPT2 to be disabled or enabled.  
The upper display shows “OPT2”. Lower dis-  
play shows “On” or “Off”. The Adjust Control  
is used to select either “On” or “Off”.  
Software Revision Level  
If the Setup push button is pressed, the unit  
displays the software version being used by  
the interface PCB (PC20).  
“OPT2” is a second input that may be used  
with an external device, such as a gas flow  
switch, to end the weld sequence. The gas  
flow switch may be used to stop the weld se-  
quence if shielding gas flow to the gun is inter-  
rupted. A closed set of contacts between pins  
1 and 2 of RC24 on Interface Board (PC20)  
will allow feeder to operate normally. Opening  
When the Setup button is pressed again, the  
menu repeats.  
Code  
the contacts will stop the weld sequence and Upon leaving the auxiliary menu, the user is  
display “ERR” in the upper display and  
“OPT2” in the lower display.  
asked if a password code indicated by  
“CODE” in the top display should be activated.  
By default the code is off, indicated by “OFF”  
in the lower display. The user may enter a nu-  
Display Hold  
Display hold indicated by ”DISP” in the upper merical password between 0 and 999 by turn-  
display is set to “OFF” or “HOLD” in the lower ing the Adjust control. When the user reen-  
display. When ”HOLD” is selected, the unit will ters the auxiliary menu, the password code  
6-11. Jog/Purge  
1
2
3
Jog/Purge Push Button  
Adjust Control  
Gun Trigger Receptacle  
2
3
802 807  
1
Pressing the Jog/Purge switch allows the op-  
erator to jog wire without energizing the weld  
power or gas valve circuit.  
trigger is still activated after two minutes, the  
jog operation is terminated to prevent com-  
plete despooling of the wire, in the case of  
a damaged gun.  
unit displays jog speed when the unit is be-  
ing jogged.  
Jogging can also be accomplished by  
pressing the Jog/Purge button.  
The unit provides the ability to jog the wire  
feeder by means of the gun trigger or the  
Jog/Purge switch. If the welding arc does  
not initiate in 3 seconds after the gun trigger  
is activated, the unit will perform a jog opera- Jog speed can be adjusted by the Adjust  
tion for a maximum of two minutes. If the gun control when the unit is jogging wire. The  
The unit displays the “ERR TRIG“ message  
to inform the operator that the trigger is acti-  
vated.  
Pressing the Jog/Purge button also allows  
the operator to purge gas lines before weld-  
ing and to preset gas pressure at the  
regulator.  
OM-1500-9 Page 24  
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SECTION 7 SETTING SEQUENCE PARAMETERS  
7-1. Sequence Parameters In A Program  
. For more information on  
Sequence Push Button see  
If time is set to zero in Weld  
sequence, welding continues until  
gun trigger is released.  
Sequence  
Parameters  
If time is set to zero in any timed  
sequence except Weld, the  
sequence is skipped.  
Volts  
IPM  
Seconds  
0-9.9  
1. Preflow  
2. Run-In  
3. Start  
4. Weld  
X
X
X
X
X
X
X
X
0.00-5.00  
0-100.0  
0-5.00  
5. Crater  
6. Burnback  
7. Postflow  
0-0.25  
0-9.9  
X = Setting available.  
Weld Time  
Crater  
Time  
Burnback  
Time  
Start  
Time  
Preflow  
Time  
Postflow  
Time  
Time  
Burnback  
Sequence  
Postflow  
Run-In  
Weld  
Start  
Crater  
Preflow  
End  
Trigger  
Released  
Trigger  
Pressed  
OM-1500-9 Page 25  
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SECTION 8 SETTING DUAL SCHEDULE PARAMETERS  
8-1. Optional Dual Schedule Switch Diagrams  
1
2
Maint 2P (Maintained-Contact  
2-Pole Switch)  
1
2
Maint 1P (Maintained-Contact  
1-Pole Switch)  
1
2
DSS-9  
1
DSS-8  
1
2
2
3
TR  
B
A
3
4
A
4
B
SECTION 9 MAINTENANCE  
9-1. Routine Maintenance  
Y
Disconnect power before maintaining.  
3 Months  
Clean and  
tighten  
Repair or  
replace  
cracked  
weld  
Replace  
unreadable  
labels.  
weld  
terminals.  
cable.  
Replace  
cracked  
parts.  
Check  
14-pin cord.  
Check gas  
hose and  
fittings.  
Check gun  
cable.  
6 Months  
Blow out or vacuum  
inside. During heavy  
service, clean  
Clean  
drive rolls.  
Or  
monthly.  
OM-1500-9 Page 26  
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9-2. Diagnostics  
1
2
3
4
Wrapper  
Motor Control Board PC1  
LED3  
DIP Switch S1  
. There is a two-position DIP  
switch S1 located on motor  
control board PC1. These  
switches are factory-set in the  
off position and must remain in  
that position for the unit to op-  
erate correctly.  
2
3
1
4
Front panel is shown removed for purpose of  
illustration only. In actual use, front panel  
would be in place.  
Ref. 802 687  
The following error messages are shown on the  
upper and lower displays to indicate specific errors.  
Explanations are in the text below:  
ERR  
ERR  
ERR  
ERR  
ERR  
OPT1  
ERR  
COM1  
TRG1  
TCH1  
MTR1  
OPT2  
Indicates a  
communication  
error.  
Indicates a trigger  
error.  
Indicates a  
tachometer error.  
Indicates a motor  
error.  
No gas flow  
detected.  
Optional error  
condition.  
LED3-RelatedError Indications  
4 blinks = Motor Error  
speed is regulated through the monitoring of  
voltage and current.  
Error conditions are indicated by LED3 on  
PC1. To view LED3, turn Off unit, remove  
wrapper, and turn unit On. LED3 is most easily  
observed from the left side of the unit.  
The LED blinks in a 2.5 second cycle. The  
number of blinks in this period indicates the  
type of error.  
ERR COM1  
ERR MTR1  
The communication error occurs 2.5 sec-  
onds after a loss of communication between The motor error indicates that the motor  
the motor and front panel boards. The user  
may continue to weld with this error. The er-  
ror may be cleared by resetting the unit (see  
Section 6-10).  
has been drawing too much current for too  
long. To remedy this, reduce the wire feed  
speed or the wire feeder torque load/duty  
cycle.  
The priority of the errors is related to the num-  
ber of blinks indicating the error. The more  
blinks, the more severe the error (motor error  
is top priority). A higher priority error overrides  
a lower one (if a motor error and a communica-  
tion error existed, the light would blink four  
times for the motor error).  
Since blink On time and blink Off time are  
equal in a four-blink cycle, the fourblink se-  
quence appears as a constant blink.  
ERR TRG1  
ERR OPT1  
The trigger error occurs if the user has the The optional 1 error indicates no coolant  
trigger held for more than two minutes with-  
out striking an arc, or if the user holds the  
trigger past the postflow phase in a timed  
weld. This error also occurs if the trigger is  
held when the feeder is powered up. The er-  
ror may be cleared by releasing the trigger.  
flow in water flow switch option. The error  
may be reset by reestablishing coolant flow  
to the gun, and then pressing any button on  
front panel.  
ERR OPT2  
The optional 2 error indicates a problem  
with optional device connected to RC24 on  
Interface Board (PC20). The error may be  
reset by correcting the problem, and then  
pressing any button on front panel.  
ERR TCH1  
1 blink = Communication Error  
2 blinks = Trigger Error  
3 blinks = Tach Error  
The tach error occurs 2 seconds after the  
loss of tachometer feedback. The user may  
continue to weld with this error. The motor  
OM-1500-9 Page 27  
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SECTION 10 ELECTRICAL DIAGRAM  
Figure 10-1. Circuit Diagram  
200 592-H  
OM-1500-9 Page 28  
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Notes  
OM-1500-9 Page 29  
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SECTION 11 PARTS LIST  
6
. Hardware is common and  
not available unless listed.  
7
5
8
9
10  
11  
12  
11  
10  
13  
15  
16  
4
17  
14  
3
2
1
18  
19  
20  
21  
802 712-A  
Figure 11-1. Main Assembly  
OM-1500-9 Page 30  
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Item  
No.  
Part  
No.  
Description  
Quantity  
Figure 11-1. Main Assembly  
. . . 1 . . . . . . . . . . . . . . . 159 647 . . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . 159 646 . . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . 159 360 . . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 4 . . . . . . . . . . . . Figure 11-3 . . Drive Assembly, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . . . . . . . . . . . . 141 753 . . Hub & Spindle Assembly, (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . . . . . . . . . . . 180 571 . . . . Shaft, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . 010 233 . . . . Spring, Cprsn .970 Od X .120 Wire X 1.250pld . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . 057 971 . . . . Washer, Flat Stl Keyed 1.500dia X .125thk . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . 010 191 . . . . Washer, Fbr .656 Id X 1.500 Od X .125thk . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 11 . . . . . . . . . . . . . . . 058 628 . . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . . . 058 428 . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . . . . . . . . . . . . 135 205 . . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . 200 556 . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . . . 201 781 . . Knob, W/Extension Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . . . 156 243 . . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . 145 639 . . Strip, Buna N Compressed Sheet .062 X 4.000 X 4.000 . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . 200 552 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . . . 134 306 . . Foot, Rubber 1.250 Dia X 1.375 High No 10 Screw . . . . . . . . . . . . . . . . . 4  
. . . 20 . . . . . . . . . . . . . . . 200 557 . . Stiffener, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . Figure 11-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-1500-9 Page 31  
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. Hardware is common and  
not available unless listed.  
1
4
8
9
10 11  
3
13  
10 12  
11  
2
23  
7
24  
14  
5
6
18  
22  
19  
15  
20  
21  
17  
802 802-D  
Figure 11-2. Control Box  
Item  
No.  
Diagram  
marking  
Part  
No.  
Description  
Quantity  
. . . 1 . . . . . . . . . . . . . . . 200 555 . . Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . 200 153 . . Overlay, Upper Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . 204 762 . . Overlay, Upper Front Panel (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . PC21 . . . . . 200 693 . . Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . PC20 . . . . . 210 559 . . Panel, PC Card Display/Micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . . . . . . . . . . . . 200 551 . . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . . . . . . . . . . 134 201 . . Stand-Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
. . . 7 . . . . . . . . . . . . . . . 200 554 . . Enclosure, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . 010 494 . . Bushing, Snap-In Nyl 1.375 Id X 1.750 Mtg Hole . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . 057 357 . . Bushing, Snap-In Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 204 910 . . Cable, Power (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . 163 519 . . . . Cable, Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Ft  
. . . 11 . . . . . . . . . . . . . . . 139 041 . . . . Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . . . . . . . . . . . . 079 739 . . . . Conn, Circ Cpc Clamp Str Rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . PLG12 . . . . 141 162 . . . . Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . PLG3 . . . . . 115 093 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . 605 227 . . Nut, 750-14 Knurled1.68dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . GS1 . . . . . 228 035 . . Valve, 34VDC 1Way .75014 Thd 2mm Orf 100PSI . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . PC1 . . . . . 217 872 . . Circuit Card Assy, Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . PC1 . . . . . 217 922 . . Circuit Card Assy, Motor Control (Low Speed Motor) . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . S1 . . . . . . 111 997 . . Switch, Rocker Spst 10a 250 VAC On-Off . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . . . 200 559 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-1500-9 Page 32  
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Item  
No.  
Diagram  
marking  
Part  
No.  
Description  
Quantity  
Figure 11-2. Control Box (Figure 11-1 Item 21) (Continued)  
. . . 20 . . . . . S2 . . . . . . 200 295 . . Switch, Rocker Spdt 15a 12v (On)-Off-(On) . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . . . . 207 741 . . Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . . . . 207 740 . . Nameplate, (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 22 . . . . . . . . . . . . . . . 213 134 . . Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . 1  
. . . 23 . . . . RC13 . . . . . 048 282 . . Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . PLG6 . . . . . 115 094 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . PLG11,61 . . . 131 005 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . PLG1 . . . . . 202 592 . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . PLG4 . . . . . 136 810 . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . PLG7,27 . . . 115 091 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . PLG10 . . . . 130 203 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 134 646 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 178 936 . . Label, Warning General Precautionary Wordless CE . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . . . . 211 989 . . Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-1500-9 Page 33  
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13  
. Hardware is common and  
19  
not available unless listed.  
11  
14  
15  
16  
See Table 11-1 For  
Drive Roll & Wire Guide Kits  
17  
18  
9
7
8
6
5
4
3
19  
2
12  
20  
1
10  
11  
21  
22  
37  
23  
24  
25  
26  
36  
35  
34  
27  
33  
28  
6
32  
31  
29  
5
30  
4
3
2
1
803 790-A  
Figure 11-3. Drive Assembly, Wire  
Item  
No.  
Diagram  
marking  
Part  
No.  
Description  
Quantity  
Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4)  
. . . 1 . . . . . . . . . . . . . . . 010 668 . . Screw, Cap Stl Sch .250-20 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 2 . . . . . . . . . . . . . . . 172 075 . . Carrier, Drive Roll W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 3 . . . . . . . . . . . . . . . 149 962 . . Spacer, Carrier Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 4 . . . . . . . . . . . . . . . 149 486 . . Pin, Rotation Arm Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 5 . . . . . . . . . . . . . . . 132 750 . . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 6 . . . . . . . . . . . . . . . 150 520 . . Spacer, Flat Stl .257 Id X .619 Od X .105 . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 7 . . . . . . . . . . . . . . . 133 493 . . Ring, Retaining Ext .250 Shaft X .025Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 8 . . . . . . . . . . . . . . . 133 350 . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . M1 . . . . . . 201 230 . . Motor, Gear 1/8Hp 24VDC Standard Speed . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . M1 . . . . . . 201 231 . . Motor, Gear 1/8Hp 24VDC High Speed (Optional) . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . M1 . . . . . . 209 131 . . Motor, Gear 1/8Hp 24VDC Low Speed (Optional) . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 153 491 . . . . Kit, Brush Replacement (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 153 492 . . . . . Cap, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . *153 493 . . . . . Brush, Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . . 184 136 . . . . Kit, Brush Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . 155 098 . . Kit, Cover Motor Gearbox (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 153 550 . . . . Cover, Motor Gearbox (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 155 099 . . . . . Gasket, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 155 100 . . . . . Screw, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
. . . . . . . . . . . . . . . . . . . . . 154 031 . . . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . . 133 493 . . . . Ring, Rtng Ext .250 Shaft Grv X .025Thk . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 203 631 . . Pressure Arm, S/L & Vert S/R 4 Roll (Consisting Of) . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . . . . . . . . . . . . 203 641 . . . . Washer, Flat Indicator Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . . . 182 415 . . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . . . . . . . . . . . . 203 640 . . . . Knob, W/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . 182 156 . . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
OM-1500-9 Page 34  
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Item  
No.  
Diagram  
marking  
Part  
No.  
Description  
Quantity  
Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4) (continued)  
. . . 15 . . . . . . . . . . . . . . . 182 155 . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 16 . . . . . . . . . . . . . . . 132 746 . . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 17 . . . . . . . . . . . . . . . 203 633 . . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . 203 632 . . . . Carrier, Shaft Dual Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . . . 133 739 . . . . Washer, Flat Buna .375 Id X .625 Od X .062Thk . . . . . . . . . . . . . . . . . . . 2  
. . . 20 . . . . . . . . . . . . . . . 203 637 . . . . Knob, W/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . PC51 . . . . . 201 225 . . Circuit Card, Digital Tach (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . PLG5 . . . . . 131 204 . . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 604 311 . . . . Grommet, Rbr .250 Id X .375mtg Hole .062 Groove . . . . . . . . . . . . . . . . 1  
. . . 22 . . . . . . . . . . . . . . . 132 611 . . Optical Encoder Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 603 115 . . Weather Stripping, Adh .125 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . . . . 167 387 . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 24 . . . . . . . . . . . . . . . 168 825 . . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . . . . 133 308 . . Ring, Retaining Ext .375 Shaft X .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . . . . . . . . . . . 134 834 . . Hose, Sae .187 Id X .410 Od (Order By Ft) . . . . . . . . . . . . . . . . . . . . . . . . 2Ft  
. . . 27 . . . . . . . . . . . . . . . 149 959 . . Fitting, Brs Barbed M 3/16tbg X .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 28 . . . . . . . . . . . . . . . 179 265 . . Adapter, Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . . . . . . . . . . . . 108 940 . . Screw, Cap Stl Hexhd .250-20 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 30 . . . . . . . . . . . . . . . 604 538 . . Washer, Flat Stl Sae .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 31 . . . . . . . . . . . . . . . 151 437 . . Knob, Plstc T 1.125 Lg X .312-18 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 32 . . . . . . . . . . . . . . . 151 290 . . Screw, Mach Stl Hexwhd 10-32 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 33 . . . . . . . . . . . . . . . 179 277 . . Cover, Drive Roll (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 196 956 . . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 34 . . . . . . . . . . . . . . . 601 872 . . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 35 . . . . . . . . . . . . . . . 602 213 . . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 36 . . . . . . . . . . . . . . . 602 243 . . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 37 . . . . . . . . . . . . . . . 601 966 . . Screw, Cap Stl Hexhd .375-16 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
*Recommended Spare Parts.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-1500-9 Page 35  
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G u i d e  
I n t e r m e d i a t e  
I n l e t G u i d e  
OM-1500-9 Page 36  
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Notes  
Work like a Pro!  
Pros weld and cut  
safely. Read the  
safety rules at  
the beginning  
of this manual.  
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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.  
Warranty Questions?  
LIMITED WARRANTY Subject to the terms and conditions  
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to  
its original retail purchaser that new Miller equipment sold after  
the effective date of this limited warranty is free of defects in  
material and workmanship at the time it is shipped by Miller. THIS  
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER  
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE  
WARRANTIES OF MERCHANTABILITY AND FITNESS.  
*
Induction Heating Coils and Blankets, Cables, and  
Non-Electronic Controls  
APT & SAF Model Plasma Cutting Torches  
Remote Controls  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
*
*
*
*
*
*
Accessory (Kits)  
Replacement Parts (No labor)  
Spoolmate Spoolguns  
Canvas Covers  
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.  
Your distributor also gives  
you ...  
Miller’s True Blue® Limited Warranty shall not apply to:  
Service  
1. Consumable components; such as contact tips,  
cutting nozzles, contactors, brushes, slip rings, relays  
or parts that fail due to normal wear. (Exception:  
brushes, slip rings, and relays are covered on Bobcat,  
Trailblazer, and Legend models.)  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
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.  
2. Items furnished by Miller, but manufactured by others, such  
as engines or trade accessories. These items are covered  
by the manufacturer’s warranty, if any.  
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.  
3. Equipment that has been modified by any party other than  
Miller, or equipment that has been improperly installed,  
improperly operated or misused based upon industry  
standards, or equipment which has not had reasonable and  
necessary maintenance, or equipment which has been  
used for operation outside of the specifications for the  
equipment.  
1. 5 Years Parts — 3 Years Labor  
*
Original main power rectifiers  
2. 3 Years — Parts and Labor  
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Process Controllers  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Sources (Unless Otherwise Stated)  
Water Coolant Systems (Integrated)  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by the  
engine manufacturer.)  
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.  
3. 1 Year — Parts and Labor Unless Specified  
*
Motor Driven Guns (w/exception of Spoolmate  
Spoolguns)  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources, Coolers, and  
Electronic  
Controls/Recorders  
*
*
*
*
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.  
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)  
Flowgauge and Flowmeter Regulators (No Labor)  
HF Units  
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND  
Grids  
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,  
Spot Welders  
Load Banks  
Arc Stud Power Sources & Arc Stud Guns  
Racks  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
Field Options  
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.  
*
(NOTE: Field options are covered under True Blue®  
for the remaining warranty period of the product they  
are installed in, or for a minimum of one year —  
whichever is greater.)  
Bernard-Branded Mig Guns (No Labor)  
Weldcraft-Branded TIG Torches (No Labor)  
Subarc Wire Drive Assemblies  
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,  
4. 6 Months — Batteries  
5. 90 Days — Parts  
*
MIG Guns/TIG Torches and Subarc (SAW) Guns  
but may vary from province to province.  
miller_warr 200601  
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Owner’s Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
For Service  
Contact a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International HeadquartersUSA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters −  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
To locate a Distributor or Service Agency visit  
www.MillerWelds.com  
Contact the Delivering Carrier to:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims, contact  
your distributor and/or equipment manufacturer’s  
Transportation Department.  
PRINTED IN USA  
© 2006 Miller Electric Mfg. Co.200601  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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