Axcess Wire Feeder

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OM-220 390U 2014−05

Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding

Description

Wire Feeder

Axcess Wire Feeder


R

CE

Visit our website at File: Advanced Manufacturing Systems


www.MillerWelds.com/ams
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.

Miller Electric manufactures a full line


of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09
TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-3. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-4. 9-Pin Network Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-6. Feeder Display At Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-7. Dual Schedule Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-3. Front Panel Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-4. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-7. Feeder Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-8. Adjust Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-9. Process Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-10. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-11. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-2. Error Code Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:
Product Stock Number
AXCESS FEEDER W/CE 195182011

Council Directives:
 2006/95/EC Low Voltage
 2004/108/EC Electromagnetic Compatibility
 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:
 IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
 IEC 60974­5:2007 Arc welding equipment – Part 5: Wire feeders
 IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
 EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)

Signatory:

October 8, 2012

_____________________________________ ___________________________________________
David A. Werba Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

241980E
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage


DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Arc Welding Hazards


disconnect box or that cord plug is connected to a properly
The symbols shown below are used throughout this manual grounded receptacle outlet.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D When making input connections, attach proper grounding conduc-
to avoid the hazard. The safety information given below is tor first − double-check connections.
only a summary of the more complete safety information D Keep cords dry, free of oil and grease, and protected from hot metal
found in the Safety Standards listed in Section 1-5. Read and and sparks.
follow all Safety Standards. D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
Only qualified persons should install, operate, maintain, and wiring can kill.
repair this unit.
D Turn off all equipment when not in use.
During operation, keep everybody, especially children, away. D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
ELECTRIC SHOCK can kill. with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input D Do not touch electrode holders connected to two welding ma-
power circuit and machine internal circuits are also chines at the same time since double open-circuit voltage will be
live when power is on. In semiautomatic or automatic present.
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are D Use only well-maintained equipment. Repair or replace damaged
electrically live. Incorrectly installed or improperly parts at once. Maintain unit according to manual.
grounded equipment is a hazard. D Wear a safety harness if working above floor level.
D Do not touch live electrical parts. D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
D Wear dry, hole-free insulating gloves and body protection.
or worktable as near the weld as practical.
D Insulate yourself from work and ground using dry insulating mats
D Insulate work clamp when not connected to workpiece to prevent
or covers big enough to prevent any physical contact with the work
contact with any metal object.
or ground.
D Do not use AC output in damp areas, if movement is confined, or if D Do not connect more than one electrode or work cable to any
there is a danger of falling. single weld output terminal. Disconnect cable for process not in
use.
D Use AC output ONLY if required for the welding process.
D Use GFCI protection when operating auxiliary equipment in damp
D If AC output is required, use remote output control if present on
or wet locations.
unit.
D Additional safety precautions are required when any of the follow- SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
ing power sources AFTER removal of input power.
as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual HOT PARTS can burn.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder D Do not touch hot parts bare handed.
is recommended. And, do not work alone!
D Allow cooling period before working on equip-
D Disconnect input power or stop engine before installing or ment.
servicing this equipment. Lockout/tagout input power according to D To handle hot parts, use proper tools and/or
OSHA 29 CFR 1910.147 (see Safety Standards).
wear heavy, insulated welding gloves and
D Properly install, ground, and operate this equipment according to clothing to prevent burns.
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
OM-220 390 Page 1
D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.

Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.


drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot Compressed gas cylinders contain gas under high
workpiece, and hot equipment can cause fires and pressure. If damaged, a cylinder can explode. Since
burns. Accidental contact of electrode to metal objects can cause gas cylinders are normally part of the welding
sparks, explosion, overheating, or fire. Check and be sure the area is process, be sure to treat them carefully.
safe before doing any welding.
D Protect compressed gas cylinders from excessive heat, mechani-
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If cal shocks, physical damage, slag, open flames, sparks, and arcs.
this is not possible, tightly cover them with approved covers. D Install cylinders in an upright position by securing to a stationary
D Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
D Protect yourself and others from flying sparks and hot metal. D Keep cylinders away from any welding or other electrical circuits.
D Be alert that welding sparks and hot materials from welding can D Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas.
D Never allow a welding electrode to touch any cylinder.
D Watch for fire, and keep a fire extinguisher nearby.
D Never weld on a pressurized cylinder − explosion will result.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. D Use only correct compressed gas cylinders, regulators, hoses,
D Do not weld on containers that have held combustibles, or on and fittings designed for the specific application; maintain them
closed containers such as tanks, drums, or pipes unless they are and associated parts in good condition.
properly prepared according to AWS F4.1 and AWS A6.0 (see D Turn face away from valve outlet when opening cylinder valve. Do
Safety Standards). not stand in front of or behind the regulator when opening the valve.
D Do not weld where the atmosphere may contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-220 390 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can injure.


D Do not install or place unit on, over, or near D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit. guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
READ INSTRUCTIONS.
extend beyond opposite side of unit.
D Read and follow all labels and the Owner’s
D Keep equipment (cables and cords) away from moving vehicles Manual carefully before installing, operating, or
when working from an aerial location. servicing unit. Read the safety information at
D Follow the guidelines in the Applications Manual for the Revised the beginning of the manual and in each
NIOSH Lifting Equation (Publication No. 94−110) when manu- section.
ally lifting heavy parts or equipment. D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
OVERUSE can cause OVERHEATING codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit. H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
FLYING SPARKS can injure. navigation, safety services, computers, and
communications equipment.
D Wear a face shield to protect eyes and face.
D Have only qualified persons familiar with
D Shape tungsten electrode only on grinder with electronic equipment perform this installation.
proper guards in a safe location wearing proper
face, hand, and body protection. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
D Sparks can cause fires — keep flammables away. tion.
D If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

MOVING PARTS can injure.


D Keep away from moving parts. ARC WELDING can cause interference.
D Keep away from pinch points such as drive D Electromagnetic energy can interfere with
rolls. sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
WELDING WIRE can injure. D Be sure all equipment in the welding area is
electromagnetically compatible.
D Do not press gun trigger until instructed to do
so. D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Do not point gun toward any part of the body,
other people, or any metal when threading D Locate welding operation 100 meters from any sensitive elec-
welding wire. tronic equipment.
D Be sure this welding machine is installed and grounded
BATTERY EXPLOSION can injure. according to this manual.
D If interference still occurs, the user must take extra measures
D Do not use welder to charge batteries or jump such as moving the welding machine, using shielded cables,
start vehicles unless it has a battery charging using line filters, or shielding the work area.
feature designed for this purpose.

OM-220 390 Page 3


1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards


Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
bustibles, American Welding Society Standard AWS A6.0, from Global Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 14501 George Carter Way, Suite www.osha.gov).
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- Applications Manual for the Revised NIOSH Lifting Equation, The Na-
net.com). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 www.cdc.gov/NIOSH).

1-6. EMF Information


Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields may interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

OM-220 390 Page 4


SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2013−09
7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

2-2. Dangers relatifs au soudage à l’arc


le sol. Dans ces conditions, utiliser les équipements suivants,
Les symboles représentés ci-dessous sont utilisés dans ce ma- dans l’ordre indiqué : 1) un poste à souder DC à tension constante
nuel pour attirer l’attention et identifier les dangers possibles. En (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
présence de l’un de ces symboles, prendre garde et suivre les souder AC à tension à vide réduite. Dans la plupart des situations,
instructions afférentes pour éviter tout risque. Les instructions l’utilisation d’un poste à souder DC à fil à tension constante est re-
en matière de sécurité indiquées ci-dessous ne constituent commandée. En outre, ne pas travailler seul !
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec- D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
tion 2-5. Lire et observer toutes les normes de sécurité. stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
mes de sécurité).
Seul un personnel qualifié est autorisé à installer, faire fonc-
tionner, entretenir et réparer cet appareil. D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil. 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
UNE DÉCHARGE ÉLECTRIQUE peut cordon est raccordée à une prise correctement mise à la terre.
entraîner la mort. D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
Le contact d’organes électriques sous tension peut teur de mise à la terre approprié et contre-vérifier les connexions.
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
sous tension lorsque le courant est délivré à la protégez−les contre les étincelles et les pièces métalliques
sortie. Le circuit d’alimentation et les circuits inter- chaudes.
nes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode D Vérifier fréquemment le cordon d’alimentation et le conducteur de
de soudage avec du fil, le fil, le dérouleur, le bloc de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
commande du rouleau et toutes les parties métalli- le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîn-
ques en contact avec le fil sont sous tension er la mort.
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
danger. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D Ne pas toucher aux pièces électriques sous tension.
D Ne pas enrouler les câbles autour du corps.
D Porter des gants isolants et des vêtements de protection secs et
sans trous. D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D 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 D Ne pas toucher l’électrode quand on est en contact avec la pièce,
pièce à couper ou le sol. la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
D Ne pas se servir de source électrique à courant électrique dans les
en même temps à cause de la présence d’une tension à vide dou-
zones humides, dans les endroits confinés ou là où on risque de
blée.
tomber.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
D Se servir d’une source électrique à courant électrique UNIQUE-
champ les pièces endommagées. Entretenir l’appareil conformé-
MENT si le procédé de soudage le demande. ment à ce manuel.
D Si l’utilisation d’une source électrique à courant électrique s’avère D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé. D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D D’autres consignes de sécurité sont nécessaires dans les condi-
tions suivantes : risques électriques dans un environnement D Fixer le câble de retour de façon à obtenir un bon contact métal-
humide ou si l’on porte des vêtements mouillés ; sur des structures métal avec la pièce à souder ou la table de travail, le plus près pos-
métalliques telles que sols, grilles ou échafaudages ; en position sible de la soudure.
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque D Isoler la pince de masse quand pas mis à la pièce pour éviter le
élevé de contact inévitable ou accidentel avec la pièce à souder ou contact avec tout objet métallique.
OM-220 390 Page 5
D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour
masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements
câble pour le procédé non utilisé. et les étincelles ; prévenir toute personne sur les lieux de ne pas
D Utiliser une protection différentielle lors de l’utilisation d’un équi- regarder l’arc.
pement auxiliaire dans des endroits humides ou mouillés. D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
Il reste une TENSION DC NON NÉGLIGEABLE dans corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
les sources de soudage onduleur UNE FOIS chaussures hautes et une casquette.
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et LE SOUDAGE peut provoquer un
décharger les condensateurs d’alimentation selon les instructions incendie ou une explosion.
indiquées dans la partie Entretien avant de toucher les pièces. Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
LES PIÈCES CHAUDES peuvent
provoquer leur éclatement. Des étincelles peuvent
provoquer des brûlures. être projetées de l’arc de soudure. La projection d’étincelles, des
D Ne pas toucher à mains nues les parties pièces chaudes et des équipements chauds peut provoquer des
chaudes. incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
D Prévoir une période de refroidissement avant de
un surchauffement ou un incendie. Avant de commencer le soudage,
travailler à l’équipement.
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Ne pas toucher aux pièces chaudes, utiliser les
outils recommandés et porter des gants de sou- D Déplacer toutes les substances inflammables à une distance de
dage et des vêtements épais pour éviter les brûlu- 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
res. soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
LES FUMÉES ET LES GAZ peuvent sur des substances inflammables.
être dangereux. D Se protéger et d’autres personnes de la projection d’étincelles et
Le soudage génère des fumées et des gaz. Leur de métal chaud.
inhalation peut être dangereux pour votre santé. D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
D Eloigner votre tête des fumées. Ne pas respirer les fumées. fissures et des ouvertures.

D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au D Surveiller tout déclenchement d’incendie et tenir un extincteur à
niveau de l’arc pour l’évacuation des fumées et des gaz de proximité.
soudage. Pour déterminer la bonne ventilation, il est recommandé D Le soudage effectué sur un plafond, plancher, paroi ou séparation
de procéder à un prélèvement pour la composition et la quantité peut déclencher un incendie de l’autre côté.
de fumées et de gaz auxquels est exposé le personnel.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
approuvé. préparés correctement conformément à AWS F4.1 et AWS A6.0
D Lire et comprendre les fiches de données de sécurité et les instruc- (voir les Normes de Sécurité).
tions du fabricant concernant les adhésifs, les revêtements, les D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
nettoyants, les consommables, les produits de refroidissement, les peurs inflammables (vapeur d’essence, par exemple).
dégraisseurs, les flux et les métaux.
D Brancher le câble de masse sur la pièce le plus près possible de la
D Travailler dans un espace fermé seulement s’il est bien ventilé ou zone de soudage pour éviter le transport du courant sur une
en portant un respirateur à alimentation d’air. Demander toujours à longue distance par des chemins inconnus éventuels en provo-
un surveillant dûment formé de se tenir à proximité. Des fumées et quant des risques d’électrocution, d’étincelles et d’incendie.
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels. D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
S’assurer que l’air de respiration ne présente aucun danger. lées.
D Ne pas souder dans des endroits situés à proximité d’opérations D En cas de non utilisation, enlever la baguette d’électrode du porte-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et électrode ou couper le fil à la pointe de contact.
les rayons de l’arc peuvent réagir en présence de vapeurs et for- D Porter un équipement de protection pour le corps fait d’un matériau
mer des gaz hautement toxiques et irritants. résistant et ignifuge (cuir, coton robuste, laine). La protection du
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier corps comporte des vêtements sans huile comme par ex. des
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- gants de cuir, une chemise solide, des pantalons sans revers, des
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit chaussures hautes et une casquette.
bien ventilé, et en portant un respirateur à alimentation d’air. Les D Avant de souder, retirer toute substance combustible de vos po-
revêtements et tous les métaux renfermant ces éléments peuvent ches telles qu’un allumeur au butane ou des allumettes.
dégager des fumées toxiques en cas de soudage.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
LES RAYONS DE L’ARC peuvent trace d’étincelles incandescentes ni de flammes.
provoquer des brûlures dans les D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
yeux et sur la peau. Ne pas augmenter leur puissance; ne pas les ponter.
Le rayonnement de l’arc du procédé de soudage D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
génère des rayons visibles et invisibles intense trace d’étincelles incandescentes ni de flammes.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
dans les yeux et sur la peau. Des étincelles sont projetées pendant le Ne pas augmenter leur puissance; ne pas les ponter.
soudage.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
D Porter un casque de soudage approuvé muni de verres filtrants NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
approprié pour protéger visage et yeux pour protéger votre visage extincteur à proximité.
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 D Lire et comprendre les fiches de données de sécurité et les instruc-
et Z87.1 énuméré dans les normes de sécurité).
tions du fabricant concernant les adhésifs, les revêtements, les
D Porter des lunettes de sécurité avec écrans latéraux même sous nettoyants, les consommables, les produits de refroidissement,
votre casque. les dégraisseurs, les flux et les métaux.
OM-220 390 Page 6
DES PIECES DE METAL ou DES LES BOUTEILLES peuvent exploser
SALETES peuvent provoquer des si elles sont endommagées.
blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser. Du fait que les
pièce à la brosse en fil de fer, et le meulage gé- bouteilles de gaz font normalement partie du
nèrent des étincelles et des particules procédé de soudage, les manipuler avec
métalliques volantes. Pendant la période de précaution.
refroidissement des soudures, elles risquent D Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
de projeter du laitier. ve, des chocs mécaniques, des dommages physiques, du lai-
D Porter des lunettes de sécurité avec écrans latéraux ou un écran tier, des flammes ouvertes, des étincelles et des arcs.
facial. D Placer les bouteilles debout en les fixant dans un support sta-
tionnaire ou dans un porte-bouteilles pour les empêcher de tom-
ber ou de se renverser.
LES ACCUMULATIONS DE GAZ D Tenir les bouteilles éloignées des circuits de soudage ou autres
risquent de provoquer des blessures circuits électriques.
ou même la mort. D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Fermer l’alimentation du gaz comprimé en cas D Une électrode de soudage ne doit jamais entrer en contact avec
de non utilisation. une bouteille.
D Veiller toujours à bien aérer les espaces confi- D Ne jamais souder une bouteille pressurisée − risque d’explosion.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application
Les CHAMPS ÉLECTROMAGNÉTIQUES spécifique; les maintenir ainsi que les éléments associés en bon
état.
(CEM) peuvent affecter les implants mé-
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
dicaux. de la bouteille. Ne pas se tenir devant ou derrière le régulateur
lors de l’ouverture de la vanne.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à D Le couvercle du détendeur doit toujours être en place, sauf lors-
distance. que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
D Les porteurs d’implants médicaux doivent consulter leur
D Utiliser les équipements corrects, les bonnes procédures et suf-
médecin et le fabricant du dispositif avant de s’approcher de la
fisamment de personnes pour soulever et déplacer les bouteil-
zone où se déroule du soudage à l’arc, du soudage par points, du les.
gougeage, de la découpe plasma ou une opération de chauffage
par induction. D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sé-
LE BRUIT peut endommager l’ouïe. curité.

Le bruit des processus et des équipements peut


affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

D Suivre les consignes du Manuel des applications pour l’équation


Risque D’INCENDIE OU de levage NIOSH révisée (Publication Nº94–110) lors du levage
D’EXPLOSION. manuelle de pièces ou équipements lourds.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables. L’EMPLOI EXCESSIF peut
D Ne pas installer l’appareil à proximité de pro- SURCHAUFFER L’ÉQUIPEMENT.
duits inflammables. D Prévoir une période de refroidissement ; res-
D Ne pas surcharger l’installation électrique − s’assurer que pecter le cycle opératoire nominal.
l’alimentation est correctement dimensionnée et protégée avant D Réduire le courant ou le facteur de marche
de mettre l’appareil en service. avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures. LES ÉTINCELLES PROJETÉES
D Utiliser l’anneau de levage uniquement pour peuvent provoquer des blessures.
soulever l’appareil, NON PAS les chariots, les D Porter un écran facial pour protéger le visage et
bouteilles de gaz ou tout autre accessoire. les yeux.
D Utiliser un équipement de levage de capacité suffisante pour lever D Affûter l’électrode au tungstène uniquement à la
l’appareil. meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer lorsque l’on porte l’équipement homologué de
que les fourches sont suffisamment longues pour dépasser du protection du visage, des mains et du corps.
côté opposé de l’appareil.
D Les étincelles risquent de causer un incendie − éloigner toute sub-
D Tenir l’équipement (câbles et cordons) à distance des véhicules stance inflammable.
mobiles lors de toute opération en hauteur.
OM-220 390 Page 7
LES CHARGES ÉLECTROSTATI- LE RAYONNEMENT HAUTE
QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque de
cuits imprimés. provoquer des interférences.
D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut
avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi-
D Utiliser des pochettes et des boîtes antista- pements de radio−navigation et de com-
tiques pour stocker, déplacer ou expédier des munication, les services de sécurité et les ordi-
cartes de circuits imprimes. nateurs.
D Demander seulement à des personnes qualifiées familiarisées
Les PIÈCES MOBILES peuvent avec des équipements électroniques de faire fonctionner l’instal-
causer des blessures. lation.
D Ne pas s’approcher des organes mobiles. D L’utilisateur est tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande. D Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
LES FILS DE SOUDAGE peuvent D Effectuer régulièrement le contrôle et l’entretien de l’installation.
provoquer des blessures. D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une dis-
D Ne pas appuyer sur la gâchette avant d’en tance correcte et utiliser une terre et un blindage pour réduire les
avoir reçu l’instruction. interférences éventuelles.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EXPLOSION DE LA BATTERIE D L’énergie électromagnétique risque de
peut provoquer des blessures. provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
D Ne pas utiliser l’appareil de soudage pour l’équipement commandé par ordinateur tel que
charger des batteries ou faire démarrer les robots.
des véhicules à l’aide de câbles de démarrage,
D Veiller à ce que tout l’équipement de la zone de soudage soit
sauf si l’appareil dispose d’une fonctionnalité
compatible électromagnétiquement.
de charge de batterie destinée à cet usage.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
Les PIÈCES MOBILES peuvent soudage aussi courts que possible, les grouper, et les poser
causer des blessures. aussi bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipe-
D S’abstenir de toucher des organes mobiles tels ment électronique sensible.
que des ventilateurs.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
D Maintenir fermés et verrouillés les portes, conformément à ce mode d’emploi.
panneaux, recouvrements et dispositifs de
D En cas d’interférences après avoir pris les mesures précéden-
protection. tes, il incombe à l’utilisateur de prendre des mesures supplé-
D Lorsque cela est nécessaire pour des travaux d’entretien et de mentaires telles que le déplacement du poste, l’utilisation de câ-
dépannage, faire retirer les portes, panneaux, recouvrements bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
ou dispositifs de protection uniquement par du personnel qua- teurs dans la zone de travail.
lifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

LIRE LES INSTRUCTIONS.


D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’instal-
lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.

OM-220 390 Page 8


2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)

2-5. Principales normes de sécurité


Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
bustibles, American Welding Society Standard AWS A6.0, from Global Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 14501 George Carter Way, Suite www.osha.gov).
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- Applications Manual for the Revised NIOSH Lifting Equation, The Na-
net.com). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM


Le courant électrique qui traverse tout conducteur génère des champs 3. Ne pas courber et ne pas entourer les câbles autour de votre
électromagnétiques (CEM) à certains endroits. Le courant issu d’un corps.
soudage à l’arc (et de procédés connexes, y compris le soudage par 4. Maintenir la tête et le torse aussi loin que possible du matériel du
points, le gougeage, le découpage plasma et les opérations de circuit de soudage.
chauffage par induction) crée un champ électromagnétique (CEM)
5. Connecter la pince sur la pièce aussi près que possible de la
autour du circuit de soudage. Les CEM peuvent créer des interférences soudure.
avec certains implants médicaux comme des stimulateurs cardiaques.
Des mesures de protection pour les porteurs d’implants médicaux 6. Ne pas travailler à proximité d’une source de soudage, ni
doivent être prises: Limiter par exemple tout accès aux passants ou s’asseoir ou se pencher dessus.
procéder à une évaluation des risques individuels pour les soudeurs. 7. Ne pas souder tout en portant la source de soudage ou le
Tous les soudeurs doivent appliquer les procédures suivantes pour dévidoir.
minimiser l’exposition aux CEM provenant du circuit de soudage: En ce qui concerne les implants médicaux :
1. Rassembler les câbles en les torsadant ou en les attachant avec Les porteurs d’implants doivent d’abord consulter leur médecin avant
du ruban adhésif ou avec une housse. de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les tion. Si le médecin approuve, il est recommandé de suivre les
câbles d’un côté et à distance de l’opérateur. procédures précédentes.

OM-220 390 Page 9


OM-220 390 Page 10
SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions


. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

Do not discard product (where applicable) with general waste.


Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe2 2012−05

Protect yourself from electric shock by insulating yourself from work and ground.

Safe3 2012−05

Disconnect input plug or power before working on machine.

Safe5 2012−05

Keep your head out of the fumes.

Safe6 2012−05

Use forced ventilation or local exhaust to remove the fumes.

Safe8 2012−05

Use ventilating fan to remove fumes.

Safe10 2012−05

Keep flammables away from welding. Do not weld near flammables.

Safe12 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe14 2012−05

OM-220 390 Page 11


Do not weld on drums or any closed containers.

Safe16 2012−05

Do not remove or paint over (cover) the label.

Safe20 2012−05

Disconnect input plug or power before working on machine.

Safe30 2012−05

Drive rolls can injure fingers.

Safe32 2012−05

Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.

Safe33 2012−05

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Become trained and read the instructions before working on the


machine or welding.

Safe40 2012−05

OM-220 390 Page 12


3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.

Output
A Amperes V Volts
Direct Current
(DC)

X Duty Cycle Wire Feed Percent


IP Degree Of
Protection

Cold Jog (Inch)


Input Towards Purge By Gas Fast
Workpiece

Constant Current Circuit Breaker Constant Voltage Slow

Trigger Hold Off Trigger Hold On I2 Rated Welding


Current
Increase

Read Instructions
U1 Primary Voltage
U2 Conventional Load
Voltage
Locked

I1 Primary Current Sequence Program Process

Variable
Wire Type Gas Type Time
Inductance

Trigger Hold On Trigger Hold


Arc Control Trigger Control
Indicator Light Off Indicator Light

Single Phase Three Phase Line Connection

Notes

OM-220 390 Page 13


SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Unit Specifications


Type of Input Welding Power Wire Feed Wire Diameter Welding Circuit Overall
Weight
Power Source Type Speed Range Rating Dimensions

40 Volts DC Axcess Series Standard: 1.0 To 0.8 To 3.2mm 100 Volts, Length: 686mm 20.9 kg
10 Amperes 35.6 mpm (40 To (.030 To 1/8 in.) 300 Amperes, (27 in.) (46 lb)
1400 ipm) Max Spool 100% Duty Cycle Width: 318mm
Capacity: 457mm (12-1/2 in.)
(18 in.)
Max Spool Weight: Height: 368mm
27 kg (14-1/2 in.)
(60 lb)

4-3. Environmental Specifications


A. IP Rating
IP Rating
IP2X
This equipment is designed for indoor use and is not intended to be used or stored outside.

B. Information On Electromagnetic Fields (EMF)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.

S The EMF assessment on this equipment was conducted at 0.5 meter.

S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10

C. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances. ce-emc 3 2011-09

OM-220 390 Page 14


SECTION 5 − INSTALLATION
5-1. Selecting A Location

Movement Tipping ! Do not move or operate


unit where it could tip.

2
OR

Location ! Special installation may be required where gasoline or volatile ! Do not stack units. Beware of
liquids are present − see NEC Article 511 or CEC Section 20. tipping.
3 1 Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side
of unit.
2 Hand Cart
Use cart or similar device to move
460 mm unit.
(18 in.)
3 Line Disconnect Device
Locate unit near correct input
power supply.

460 mm
(18 in.)
loc_2 3/96 - Ref. 803 502-B

5-2. Connection Diagram


1 Welding Power Source
2 Wire Feeder
3
3 Gas Cylinder
4 Gas Hose
4
5 Network Feeder Cable
6 Negative (−) Weld Cable
7 Workpiece
8 Voltage Sensing Lead
Recommended for Accu-pulse and
2 5 RMD (optional).
1
. Positive (+) voltage sensing
lead is contained in the motor
cable.
7
9 Positive (+) Weld Cable

9
8
6

Ref. 801 915 / Ref. 803 501-B

OM-220 390 Page 15


5-3. Rear Panel Connections And Rotating Drive Assembly
1 9-Pin Network Receptacle
2 Shielding Gas Valve Fitting
Requires fitting with 5/8-18 right-
hand threads. Connect customer-
supplied gas hose.
7 3 Weld Cable Terminal
1 4 Weld Cable
5 Drive Assembly
2 6 Drive Assembly Rotation
Knob
7 Rating Label Location
To rotate the drive assembly,
loosen drive assembly rotation
knob, rotate drive assembly, and
tighten knob.

Tools Needed:
5 9/16, 5/8 in.
3/16 in.

802 825-A / 803 503-B / Ref. 246 041-B

5-4. 9-Pin Network Receptacle Information


Pin Pin Information
9

A Capacitor C1 to ground
B Shield
C Volt sense
F G
D Can low
E H
E Can high
D I
A F +24 volts DC common
C B
G + 24 volts dc
H Motor voltage +40 volts DC common

I Motor voltage +40 volts DC

OM-220 390 Page 16


5-5. Installing And Threading Welding Wire

Install wire spool. Adjust tension nut so Install wire guides and
wire is taut when wire feed stops. anti-wear guide.

Install drive rolls.

Pressure
Indicator
Pressure Scale
Adjust
Rear Pressure
Rolls Adjust
Front
Rolls

No Wire Slip Wire Slips


NONCONDUCTIVE NONCONDUCTIVE
SURFACE SURFACE

Drive Rolls Tools Needed:

Gun Cable 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 steel wire, reduce drive roll pressure on about 2 in. (51 mm) from nonconductive
installing gun, position liner the rear roll to half that of the front rolls. surface and press gun trigger to feed wire
extending from outlet wire guide as against surface. Tighten knob so wire
close as possible to drive rolls without does not slip. Do not overtighten. If
touching. contact tip is completely blocked, wire
should slip at the feeder (see pressure
adjustment above).Cut wire off. Close
Install gun. Lay gun cable out straight. Cut off
cover.
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-220 390 Page 17


5-6. Feeder Display At Power Up
1 1 Upper Display
2 Lower Display

V t 2

Process Setup Adjust Feeder Setup

Power Source Upper Display Lower Display Voltage Range

Net Wait

DTEC OFF

Axcess Axcs 300/450/675 10 44

219 711-A

5-7. Dual Schedule Switch Option


1 Maint 2P (Maintained-Contact
2-Pole Switch)
DSS-9M Part No. 041 793

1 DSS-9M 1

2 2

1
A 3

B 4

OM-220 390 Page 18


Notes

OM-220 390 Page 19


SECTION 6 − OPERATION
6-1. Operational Terms

The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:

General Terms:
AccuCurve CV Pulse process using a pulse waveform with modified curves at particular locations within the wa-
veform. Has a distinguished change in arc characteristics. Front panel display is ACCU − CURV.
Accu-pulse Pulse process utilizing constant current ramps with constant voltage control of peaks and
backgrounds. Adaptive response is controlled by peak and minimum current levels. Benefits are
shorter arc lengths, better puddle control, more tolerant of tip-to-work variation, less audible noise, no
arc wandering, allows weld to fill in at toes increasing travel speed and deposition, and more tolerant
to poor fit up and gaps.
Accuspeed (Optional) CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is de-
signed to be tight and fast. Front panel display is ACCU − SPED.
Adjust Control knob used to change or set parameters and functions.
Amps Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases
the actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by
volts in MIG programs.
Arc Control Allows setting of inductance in MIG mode. In pulse and Accu-pulse mode, this adjustment changes
the arc cone by adjusting the preprogrammed factory pulse data. In RMD (optional), this control will
affect the in much the same way as inductance.
Arc Length Distance from end of wire electrode to workpiece.
Auto Thread Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously
will automatically feed wire. Default setting is 192 at a feed rate of 700 ipm (these values can be
changed using a PDA with File Management/WaveWriter software). Pressing jog, purge, or trigger
switch will terminate the auto-threading feature.
Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends.
DS (Dual Schedule) Dual Schedule allows selecting a pair of programs that can be used together.
Feeder Set Up Allow selection of Sequence and trigger functions.
Gas Type Selection of shielding gas being used in application.
Inductance In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit
transfers per second (provided no other changes are made) and increase the arc-on time. The
increased arc-on time makes the welding puddle more fluid.
MIG CV weld process with individual settings of voltage and wire speed.
Postflow Setting a time value for gas flow after arc end.
Preflow Setting a time value for gas flow prior to arc start.
Process A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
Process Set Up Selection procedure for entering program.
Program Eight active slots for selection of various processes, wire type, and parameters.
Program Load Enters selected program information into program slot.
Pulse Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as
factory taught data. Adaptive method is controlled by frequency adjustment.
RMD (optional) RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of
RMD are well suited to thin materials, improves gap filling and spatter reduction. Provides less heat
input into workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge
materials.
Sequence Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters.
Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only
adjustable with the optional PDA with File Management/WaveWriter software).
TDS (Trigger Dual Schedule) TDS allows the operator to select between a pair of weld programs by using the gun trigger. In TDS
mode, momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected
weld programs.
TH (Trigger Hold) Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger. In trigger
hold mode, momentarily press gun trigger, and wire will feed until gun trigger is momentarily pressed
again.

OM-220 390 Page 20


General Terms:
Time Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in
the Arc On and Analog input or the Arc On and No Analog input modes).
TPS (Trigger Program Schedule) TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily
pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total
of 8 programs.
Trigger Control Selecting Trigger Control allows activating trigger functions such as DS, TH, 4T, TDS, and TPS.
Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of
weld.
Wire Type Selection of wire type by alloys and classification.
WFS Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage
setting. In pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power
level on wire electrode (one knob control).
4T 4T allows the operator to select between weld parameters and crater parameters using the gun
trigger. Crater time must be set for at least 0.2 seconds to make this function operational. If gun
trigger is released during welding, unit goes into trigger hold, then pressing and holding trigger again
causes unit to stay in crater until trigger is released and crater parameter times out.

6-2. Power Switch


1 Power Switch

803 504-B

OM-220 390 Page 21


6-3. Front Panel Sections

See
Section 6-5

See
Section 6-4
See
V t Section 6-6

Process Setup Adjust Feeder Setup

See See See


Section 6-9 Section 6-8 Section 6-7

219 711-A

OM-220 390 Page 22


6-4. Program Push Button
1 Program Display
The number of the active program
is displayed.
2 Program Push Button
3 Program Push Button LED
The LED lights to indicate that
1 programs can be changed using
the Adjust knob.
Momentarily press button to
illuminate LED. To change the
program number, rotate Adjust knob
3
to select one of eight programs.
2 Pressing and holding the push
button will display current wire size,
wire type and process.
To reset feeder to factory settings,
turn power source off for 10
seconds. Press and hold button in
on power up, wait until top display
shows RST and bottom display
shows NO before releasing button.
Feeder Set Up button LED will
begin flashing. Turn Adjust knob to
change bottom display to show
YES, then press Feeder Set Up
button to confirm selection. The top
display will show CYCL and the
lower display will show PWR. Turn
welding power source power off for
10 seconds, then turn power back
on again.

6-5. Upper Display

3
1
2
4

V
5

1 Upper Display illuminates to indicate that information Adjust knob. The preset values will be
displayed can be changed by the Adjust knob. displayed while the knob is being rotated
The upper display at idle (not welding) shows
preset volts with process selection MIG or Arc 4 Volts LED and return to displaying actual values
Adjust for all other processes. When welding, when adjustment is completed.
Indicates a voltage value is being displayed,
the display shows actual voltage. The display preset voltage in MIG when not welding and To activate Carbon Arc Cutting (CAC), press
will show actual voltage for approximately 3 actual voltage while welding. and hold the upper display push button in on
seconds after welding stops before returning power up. CAC will appear on the upper
to preset value. 5 Arc Adjust LED display and NO will appear on the lower
Indicates that displayed value is an arc length display. Rotate adjust knob to YES on the
2 Upper Display Push Button lower display, and press the flashing Feeder
value when the process is Pulse, Accu-pulse,
Press the button to illuminate the LED and or RMD (optional). Set up push button . CYCL will appear on the
allow changing information in the display. upper display and PWR will appear on the
3 Upper Display Push Button LED
. At any time while welding, the display lower display. Turn welding power source off
allows adjustment of the weld voltage or and back on again to enable the Carbon Arc
The upper display push button LED arc adjust preset values by turning the Cutting process selection.

OM-220 390 Page 23


6-6. Lower Display

5
7
t
1
6

A
3 4

1 Lower Display 4 Arc Ctl (Arc Control) LED During a welding program operation, it is
LED illuminates to indicate that inductance possible to change WFS (wire feed speed) by
The lower display shows WFS (wire feed (MIG) or ARC [Pulse, Accu-pulse, or RMD using the Adjust knob regardless of the active
speed), AMPS (amperage), ARC CTL (arc (optional)] is being displayed and can be program sequence that appears on the dis-
control), or Time. The feeder displays only adjusted using the Adjust knob. play.
preset wire speed at idle (not welding). While
5 Time LED When the Arc Ctl LED is illuminated, it is
welding, the average amperage is displayed.
The lower display shows welding sequence LED illuminates to indicate that a time value is possible to change values while welding by
time when the Time LED is illuminated. being displayed for a sequence function and using the Adjust knob. To return to actual
can be adjusted using the Adjust knob. values on the display, exit the Arc Ctl display.
2 WFS (Wire Feed Speed) LED 6 Lower Display Push Button
7 Lower Display Push Button LED
. The lower display push button has
LED illuminates to indicate the preset wire feed additional functions when entering the
Pressing the button illuminates the LED and sequence and trigger control functions
value is being displayed and can be adjusted
selects either WFS or Arc Ctl value for (see Section 6-7).
using the Adjust knob.
changing using the Adjust knob.
3 Amps LED To select Arc Ctl, press and hold lower display
button for 2 seconds. The top display will show
LED illuminates to indicate the average either INDU for a MIG program or ARC for
amperage is being displayed while welding Pulse, Accu-pulse, or RMD (optional). To exit
and for 3 seconds after welding is terminated. Arc Ctl or INDU, either press the upper display
The amperage must be above a minimum push button or press and hold the lower display
value of 25 amps for this function to operate. push button for 2 seconds.

Notes

OM-220 390 Page 24


6-7. Feeder Set Up Push Button

3
Start Crater
4 Time Time

Preflow
Time Postflow
1 Time

5 Sequence Diagram

Feeder Setup

1 Feeder Set Up Push Button LED pushing the Lower Display push button a off. Not all trigger control methods are
2 Feeder Set Up Push Button second time, while STRT or CRTR appear compatible with each other, therefore,
in the upper display, allows entering voltage turning on certain trigger selections will
 Press button to choose Sequence. Feeder
(MIG) or Arc Adjust [Pulse, Accu-pulse, or cause other trigger selections to turn off.
Set Up push-button LED will illuminate.
RMD (optional)]. Use the Adjust knob to  Press the lower display push button to
3 Sequence LED change the values indicated by the flashing illuminate the push-button LED and enable
 When the Feeder Set Up button is pressed LED for either Volts or Arc Adjust. Pressing the use of the Adjust knob to allow turning
once, the Sequence LED will illuminate and the Lower Display push button a third time selected trigger control methods on or off. If
the upper display will show sequence will activate the WFS setting for either STRT trigger hold is set to on, the Trigger Hold
options. Use the Adjust knob to select PRE or CRTR and the WFS LED will begin LED will illuminate.
(preflow), STRT (start), CRTR (crater), or flashing. Use the Adjust knob to change the
POST (postflow). WFS value. . Trigger Hold is automatically set to On
 Press the lower display push button and the  Pressing the Feeder Set Up button two with the 4T trigger selection. This is part
Lower Display push-button LED will more times will exit the Sequence menu and of the 4T function.
illuminate as well as the lower display. The return the system to standby mode.  Press the Feeder Set Up button a third time
Time LED will automatically begin flashing 4 Trigger Control LED to cycle back to standby mode.
indicating that a time value can be entered  Press the Feeder Set Up button twice and 5 Lock LED
by turning the Adjust knob. By entering a the Trigger Control LED will illuminate, and  The lock LED is illuminated when one or more
time value the sequence state will become the upper display will show the different programs have been locked using an optional
active. To turn off a sequence state, change trigger control selections. Use the Adjust PDA with File Management/WaveWriter
the time value to OFF. To step back for knob to cycle through the trigger control software. This indicates that some programs
selecting another sequence option, press methods as follows: DS, TH, TDS, TPS, and have been disabled. A disabled program will
the Upper Display push button. 4T (see Section 6-1 for definitions). The not show up for selection.
 The Sequence option STRT and CRTR will lower display will show the current state of Refer to the File Management/WaveWriter
have additional parameter settings. By each trigger control method as being on or Owner’s Manual for additional information.

6-8. Adjust Knob


1 Adjust Knob
The Adjust knob is used to change
functions and parameters. Refer to
the front panel sections for
information regarding use of this
control.
1

Adjust

OM-220 390 Page 25


6-9. Process Set Up Push Button
1 Process Set Up Push Button
2 Process Set Up LED
3 Program Selection LEDs

Process Setup

 Press the Process Set Up push button the  Pressing the Process Set Up push button a  If a custom program is loaded using an
first time will illuminate the button LED and fourth time will keep Wire Type LED lit and optional PDA with File Management
the Process LED. The upper and lower the upper display will show wire size. The software, the Program Display will have a
displays will be used for Accu-pulse and upper display push button will be flashing “C” in front of the program number. This
only the lower display for MIG, Pulse and indicating that turning the Adjust knob will indicates that the program is not a factory
RMD (optional) to show the current process select wire sizes available for that particular default program and has been modified. By
installed in this program. To change process and wire type. selecting or changing any process variable
process, turn the adjust knob.  Pressing the Process Set Up push button a and performing a program load will restore
fifth time will illuminate the Gas Type LED the program back to the factory default
 Pressing the Process Set Up push button a
and the lower display will show GAS and the program.
second time will illuminate the Wire Type
upper display will show gas selection (see
LED and the lower display will show wire
Table 6-1 for gas abbreviations). To make a
types available for selected processes (see  Pressing and holding the Process Set Up
gas type selection, turn the Adjust knob.
Table 6-1 for wire abbreviation). To make a push button in on power up allows viewing
selection, turn the Adjust knob.  If any of the Process, wire type, alloy type,
wire size, or gas type was changed, then the software revisions of each circuit board
 Pressing the Process Set Up push button a pressing the Process Set Up push button a in the system. The top display shows the
third time will keep Wire Type LED lit and the sixth time will show PROG in the upper board (PCM, UIM, WFCM, and AIM
upper display will show wire alloy type (see display and LOAD in the lower display. The (automated units only) and the lower display
Table 6-1 for alloy types). The upper display new program would be loaded for that shows the last 3 digits of the circuit board
push-button LED will be flashing indicating particular program in slot 1 thru 8. If no part number plus a letter designator. Press
that turning the Adjust knob will change the changes were made to any setup items, no the flashing Feeder Set Up push button to
alloy type for the selected process and wire program will be loaded, and unit will return exit the screen displays and continue the
type. to standby mode. power up process.

Table 6-1. Welding Wire And Gas Abbreviations*

Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation
Steel STL E70, E100, E120 100% CO2, CO2
90% Argon/10% CO2, C10
85% Argon/15% CO2, C15
75% Argon/25% CO2, C25
95% Argon/5% CO2, C5
95% Argon /5% O2, OX5
98% Argon/2% O2 OX2
Stainless Steel SS 308, 309, 312, 316 98% Argon, 2% O2 OX2
(81Ar/18HE/1CO2 Tri Gas
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO2 Tri Gas
MIG/RMD/Accu-pulse)
Cored Tubular Wire MCOR 71, 76, 86R, 409, 439 90% Argon/10% CO2 C10
98% Argon/2% O2 OX2
Aluminum ALUM 4XXX, 5XXX 100% Argon ARGN
* Not all wire types may be available with your unit.

OM-220 390 Page 26


6-10. Jog/Purge

1 Jog/Purge Push Button


2 Adjust Knob
3 Gun Trigger Receptacle

803 505-A

The Jog/Purge switch provides the following display. After 3 seconds the weld output  Pressing right side of the Jog/Purge switch
functions: turns off and the wire will feed at 50 ipm for allows the operator to purge gas lines before
the next 3 seconds and then ramps up to welding and to preset gas pressure at the
 Pressing left side of the Jog/Purge switch 700 ipm until trigger is released or 30 regulator.
allows the operator to feed wire without seconds elapses. If the gun trigger is still
energizing the weld power or gas valve activated after 30 seconds, the jog
circuit. The wire will feed at a 50 ipm rate for  This unit is equipped with Auto Thread
operation is terminated to prevent complete
3 seconds, then the rate ramps up to 700 unspooling of the wire and an “ERR STRT” capability. By rocking the switch from purge
ipm until the Jog switch is released. message is displayed on the upper and to jog within 0.5 seconds will automatically
lower displays. Releasing and pressing the feed wire for a factory default setting of 192
 The unit also provides the ability to jog the trigger again will clear the error. in (4877 mm) of wire before stopping. The
wire feeder by means of the gun trigger. default feed rate is 700 ipm. These settings
When the gun trigger is pressed without . If Start Error is enabled using an optional can be changed using an optional PDA with
starting an arc, the wire will feed at run-in PDA with File Management software, an File Management software. Pressing the
speed for the first 3 seconds. During this “ERR STRT” will occur after the first 3 Jog/Purge switch or gun trigger during Auto
time OCV (open circuit voltage) will be seconds of run in and jogging from the Threading will terminate the automatic feed
present as indicated on feeder upper trigger is not possible. operation.

OM-220 390 Page 27


6-11. Reset Mode
. Reset mode is not active when
Program Lock is enabled.
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
RST . System configuration data will be
V
lost during the Reset operation.
NO A
A

Setup Adjust Arc Control

Enter reset mode by turning power On and pressing the Program Push Button until the RST
NO message is displayed. RST NO message will not display until after the power-up
sequence is completed (approximately 20 seconds).

RST RST CYCL


V V V

YES A YES A PWR A


A A A

Setup Adjust Arc Control Setup Adjust Arc Control Setup Adjust Arc Control

Rotate Adjust knob to change NO Press the Arc Control button to Cycl Pwr message appears on the display
to YES. confirm the reset. when programs complete loading.
The reset message is displayed for Turn power off, wait 10 seconds, and turn
2 seconds while factory program power back on again to complete the reset
settings are being reloaded. operation.
During the reset mode the following
factory default programs are loaded
. After Reset is complete, be sure to load
appropriate programs that contain the
into the unit:
correct wire size, process, and shielding gas
for the welding operation
Program 1 Pulse
0.9 Mild Steel
90% Argon, 10% CO2
Program 2 MIG
0.9 Mild Steel
75% Argon, 25% CO2
Program 3 Accu-pulse
0.9 Mild Steel
90% Argon, 10% O2
Program 4 Pulse
1.1 Mild Steel
90% Argon, 10% CO2
Program 5 MIG
1.1 Mild Steel
75% Argon, 25% CO2
Program 6 Accu-pulse
1.1 Mild Steel
90% Argon, 10% O2
Program 7 Pulse
1.3 Mild Steel
90% Argon, 10% CO2
Program 8 MIG
1.3 Mild Steel
75% Argon, 25% CO2
198 993 / 803 504-B

OM-220 390 Page 28


SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence mode, see Feeder
Set Up Push Button in Section
6-7.
Weld Time can only be set by using
Sequence Parameters an optional PDA with File
Management/WaveWriter software.
Volts/Arc mpm If time is set to zero in any timed
Seconds
Adjust (IPM) sequence, the sequence is skipped.

1. Preflow Off-5.0 . Maximum IPM may actually be


lower depending on the process
and wire type selection.
2. Postflow Off-5.0

10.0-44.0/ 1.0−35.5
3. Start Off-5.0
0-99 (40-1400)

10.0-44.0/ 1.0−35.5
4. Crater Off-5.0
0-99 (40-1400)

Weld

Crater
Time

Start
Preflow Time
Postflow
Time Time

Preflow Start Weld Crater Postflow Sequence


End
Trigger Trigger
Pressed Released

OM-220 390 Page 29


SECTION 8 − MAINTENANCE AND TROUBLESHOOTING
8-1. Routine Maintenance

! Disconnect power . Maintain more often


before maintaining. during severe conditions.

n = Check Z = Change ~ = Clean l = Replace Reference


* To be done by Factory Authorized Service Agent

Every l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose nl Weld Cables
3
Months

nl Cords nl Gun Cables nl Cracked Parts


Every
6 OR
Months

~ Drive Rolls ~ Inside Unit

Notes

OM-220 390 Page 30


8-2. Error Code Troubleshooting Tables

ERR
Display Example

TACH
. The following error codes may appear on the upper and lower displays of the User Interface Module to indicate specific errors. Explanations of
the error codes are provided in the sections referenced.

User Interface Module User Interface Module


Error Type Reference
Upper Display Lower Display

Emergency Stop E STOP Section 8-2. A

Arc Error ERR ARC Section 8-2. B

No Coolant Flow ERR COOL Section 8-2. C

Ground Current
ERR GND Section 8-2. D
Detect Error

Line Error ERR LINE Section 8-2. E

Motor Over Current ERR MOTR Section 8-2. F

Arc Start Error ERR STRT Section 8-2. G

No Tach Error ERR TACH Section 8-2. H

Thermal Over
ERR TEMP Section 8-2. I
Temperature

Unknown Error ERR UNKN Section 8-2. J

Motor Communications Error MOTR COMM Section 8-2. K

Over Average Current OVER AVE Section 8-2. L

Over Current OVER CRNT Section 8-2. M

Release Trigger REL TRIG Section 8-2. N

Trigger Stuck TRIG STUK Section 8-2. O

Wire Feed Speed ERR WFS Section 8-2. P

Flow Error ERR FLOW Section 8-2. Q

Stop Error ERR STOP Section 8-2. R

Stuck Error ERR STUK Section 8-2. S

Weld Wait WELD WAIT Section 8-2. T

Please Wait PLS WAIT Section 8-2. U

Low Wire Feed Speed LOW WFS Section 8-2. V

Robot Memory ROBT MEM Section 8-2. W

Unit Communication UNIT COMM Section 8-2. X

RMD Done RMD DONE Section 8-2. Y

Gas Flow Error ERR GAS Section 8-2. Z

Robot Communication Error ROBT COMM Section 8-2. AA

Network Wait NET WAIT Section 8-2. AB

Cycle Power CYCL PWR Section 8-2. AC

PCM Bus Communication —— —— Section 8-2. AD

RIO Bus Communication —— —— Section 8-2. AE

Wire Feed Bus Communication —— —— Section 8-2. AF

UIM Bus Communication —— —— Section 8-2. AG

OM-220 390 Page 31


A. Emergency Stop Error
Indicates an emergency stop error.
Receptacle RC5-1 connects to receptacle RC1-4 and receptacle RC5-2 connects to receptacle RC4-2 on E-Stop board
PC12. A closure between RC4-1 and RC4-2 allows +24 volts DC to be supplied to the four relays on E-Stop board PC12.

In an E-Stop situation (relays open), all four relays on the E-Stop board de-energize and cut power to the control boards.

When relay CR1 on E-Stop board PC12 is de-energized, it drops out the 18 volts AC from transformer T1 that powers the
E inverter control board(s).

When relay CR2 on E-Stop board PC12 is de-energized, it breaks the contactor signal being sent to the inverter engine
STOP board(s) from the process control module PC4 (J2-9 to RC2-3) and causes a loss of signal to the AIM board (RC2-1 and
RC2-2) and to micro input (RC5-3 and RC5-4), signaling an E-Stop is active.

When relay CR3 on E-Stop board PC12 is de-energized, it breaks the secondary side output of the motor board before it
goes to the filter board.

Relay CR4 on E-Stop board PC12 is a soft start relay in parallel with the contacts of relay CR1.

B. Arc Error

ERR Indicates voltage has exceeded the programmable limit of a valid arc for the programmed amount of time (default time is
500 ms). Check contact tip, weld conditions, and shielding gas.
Arc error can be enabled or disabled using an optional PDA with File Management/WaveWriter software.
ARC

C. No Coolant Flow Error

ERR
Indicates no coolant flow in water flow switch option. The error may be reset by reestablishing coolant flow to the gun, and
then pressing the Jog/Purge button.
COOL

D. Ground Current Detect Error

ERR
Indicates that weld current is flowing through the primary ground. This is a latching error and welding power source power
must be cycled off and back on again.
GND

E. Line Error
Indicates that primary power has dropped below the operating point of the welding power source. Signal is sent from in-
verter engine module(s) (RC6, Pin 9 on inverter control board PC1) to process control module PC4 (J2, Pin 1). Check for a
ERR brown-out condition. The primary boost capacitors have dropped below an acceptable minimum voltage threshold.
This circuit monitors the 940 volts primary DC bus voltage across the electrolytic capacitors C1 and C2. Low line is dis-
played when this voltage drops below 858 volts DC. This could happen when attempting to draw near rated output power
LINE with an input voltage below 190 volts AC, three phase. This causes the boost section to go into current limit trying to sup-
ply the output power. Once current limit is reached, the boost section can no longer hold the bus capacitors at 940 volts
DC. The inverter control will also go into an output current limit mode in an attempt to supply output power.

F. Motor Over Current Error

ERR
Indicates that the motor has been drawing too much current for too long a time period. To remedy this fault, reduce the wire
feed speed or the wire feeder torque load/duty cycle. Press Jog/Purge button to clear error.
MOTR

OM-220 390 Page 32


G. Arc Start Error

ERR Indicates the contactor either is or was active, but the system failed to start an arc. Conditions for a valid arc start are at
least 50% of arc start current, voltage less than 60 volts, and voltage greater than min. valid arc voltage (default is 22.5
volts). This situation is usually attributed to a contact tip or feeder issue. The arc start error parameter can be disabled
STRT using an optional PDA with File Management/Wave Writer software.

H. No Tach Error
Indicates loss of tachometer feedback. Determine cause of error as follows:
S Press JOG button on the front panel.
S Does the motor run wide open immediately?
S YES  Replace Motor Board PC6.
ERR S Does the motor ramp up in speed?
S YES  Bad motor tach. Contact nearest Factory Authorized Service Agent.
TACH S Does the motor respond at all?
S YES  Contact nearest Factory Authorized Service Agent.
S Check motor cable. Is it damaged?
S YES  Replace motor cable.
S NO  Contact factory service personnel.

I. Thermal Over Temperature Error


Indicates one or more of the inverter engines overheated. Sent from inverter engine module(s) (RC6, Pin 12, on inverter
control board PC1) to process control module PC4 (J2, Pin 7). Check fan on inverter engine(s) and weld currents.
This signal is the sum of two conditions: shutdown that comes from the temperature monitoring circuit on the inverter con-
trol board, and Pwr-Up-Cnt that generated by the boost section of the inverter control board. When either of these signals
is active, RC6-12 is pulled low (this is the not ready line out of the inverter control board).
Shutdown is active when there is an over-temperature condition on the primary or secondary heatsink or on the boost
inductor. To determine which of the two locations is at fault, check LED 1 and LED 2 on inverter control board PC1.
S If LED 1 is lit, this indicates an over-temperature condition on the primary heat sink.
ERR S If LED 2 is lit, this indicates an over-temperature condition on the secondary heat sink or on the boost inductor.
Pwr-Up-Cnt (power up control) monitors primary voltage start-up conditions when the power source is first turned on. This
signal is opto-isolated from the boost section of the inverter control board. The following conditions must be met for the
TEMP power source to power up:
S Auxiliary power board PC3 must be powered up and operating to supply prepower of +15 volts DC to the boost sec-
tion of inverter control board PC1.
S The peak voltage of the input line power must be greater than 150 volts peak.
S The DC bus voltage must be greater than 85% of the rectified line voltage. This bus voltage also turns on the
pre-charge relay.
S The DC bus voltage must be boosted to greater than 858 volts DC.
If any of these conditions are not met, then receptacle RC6-12 is pulled low and weld output is locked out.

J. Unknown Error

ERR
Indicates error bit from process control module PC4 is set, but error value sent does not match anything defined with the
UIM board PC7.
UNKN

OM-220 390 Page 33


K. Motor Communications Error
The motor board has lost communication with the PCM board PC4. Check cabling and cable routing for boom system
motor cable and secondary cables. Separate cable as much as possible.
Check if WFM board PC6 code is installed and if microprocessor is running. Check LED3 and LED4 on WFM board PC6.
Depending on the wire feed speed, check for 0-40 volts DC on J17-3 to J17-1. If there is no voltage present there, check
for 40 volts DC at J16-1 to J16-2. If voltage is present there and neither LED is lit (Red or Green), try to download WFM
code to welding power source. If neither LED turns on after downloading code and cycling power, replace WFM board
PC6.
If LED3 and LED4 are flashing Red or Green or they are solid Red, this indicates the WFM board is still not communicating
with the PCM board PC4. Be sure that the UIM board PC7 is on-line (two green LEDs lit).
S Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
S Check process control module PC4 for +24 volts DC at 6-pin connector J6-2 (+) and J6-5 (−).
MOTR If +24 volts is not present at the connector, proceed as follows:
S Disconnect connector J10 and J11 from WFM board PC6. Check for +24 volts DC at J10-2 (+) and J10-5 (−), and
J11-2 (+) and J11-5 (−). One of the two connectors must measure +24 volts DC to ensures that the Devicenet lines
COMM are being sent from process control module PC4 to WFM board PC6. If +24 volts DC is present at either connector,
replace WFM board PC6.
S If +24 volts DC is not present at either J10 or J11 connector, check process control module PC4 at connectors J6, J7,
and J8.Remove plugs from connectors and check for +24 volts DC at pin2 (+) and pin 5 (−). If +24 volts DC is not
present at any of the connectors, replace process control module PC4.
If LED3 and LED4 are both green this indicates that the WFM board went off-line and then recovered which is usually due
to noise interference.
S Check wire drive motor isolation. Isolated portion of motor housing should not touch robot arm, welding power source
chassis, lifting eye bolts, or weld secondary common. Measure impedance between chassis and both weld secondary
commons. Measure the impedance across motor isolation barrier on motor housing. All measurements should read
high impedance.
S Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.

L. Over Average Current Error


Output current is exceeding the thermal capabilities of the welding power source for approximately 25 seconds.
Default value is as follows:
Axcess 450 limit is 610 A average
This is a duty cycle error and requires 5 minutes with power on and NO welding to clear the error.
This error indicates that an excessive amount of current was drawn over a short period of time. Over-average current is
drawn for a period of approximately 25 seconds and can also be expressed as exceeding the power source duty cycle.
The current limit is as follows:
OVER Axcess 450 is 610 amperes
This alarm cannot be reset. To clear the condition, the power source must be turned on and allowed to idle for approxim-
ately 5 minutes. This cooling period is determined by an internal timer, and turn off power will not reset the timer since it is
AVE saved with the Configuration data. After the 5 minute cooling period, press the Jog or Purge button, or cycle power to clear
the alarm.
If this alarm was received by mistake, and the power source did not exceed the duty cycle, check the following:
Check current feedback signal either while welding or connecting to a load bank. Measure between test point TP8 and
grounding strap on process control module PC4. Test point TP8 is located on left-hand side of board, about 1 in. (25 mm)
to the right of connector J11. TP8 is scaled: 1 volt measured equals 100 amperes actual. This measurement should read 0
volts when not welding. If the measurement reads approximately 13 volts DC, disconnect LEM device from engine (one at
a time) to determine if either device is bad. If the voltage reading still does not change, unplug the lower inverter control
board; if the reading remains the same, replace the upper inverter control board. Voltage readings should be present while
welding. If voltage readings are not correct for current feedback scaling, check individual inverter engines.

OM-220 390 Page 34


M. Over Current Error
Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6,
Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6).
The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip
this circuit, only a fault will cause an over-current condition. LED4 will be lit on the inverter control board, and power must
be cycled to clear this error.
OVER S The most likely fault to trip this circuit is an open 940 volts DC bus bleeder resistor, either R1 or R8 on the interconnect
board. An open resistor will cause the bus, which is split between two series capacitors, to become unbalanced. The
capacitor with the open resistor will go to approximately 340 volts DC. The other capacitor will go to approximately 600
CRNT volts DC. Normally, both capacitors are at approximately 470 volts DC. The unit will weld like this most of the time. A
16 uF balancing capacitor in series with the transformer can keep the transformer from saturating under these adverse
conditions. Occasionally, the inverter transformer will saturate, and when this happens, it draws a huge amount of
current and trips the over-current circuit. This condition locks off the inverter control board and eventually the bus ca-
pacitors will fail. A change to a different resistor eliminated this situation and the problem is no longer an issue.
S A shorted output diode will cause an over-current error and no weld output will be available.

N. Release Trigger Error

REL Indicates a timed weld has expired, but the trigger is still active. Press Jog/Purge button to clear error.
This error occurs after a timed weld expires and the trigger is not released. A PDA with File Management/WaveWriter
software can be used to set up timed welds. This is strictly an informational−type error.
TRIG

O. Trigger Stuck Error


Indicates the welding power source was turned on and the trigger signal attempted to weld. Turn welding power source off
and back on again to clear the error.
TRIG This error indicates a trigger source was activated while the power source was being powered up. If the trigger source is
removed, the error can be cleared.
S Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the source of the contactor or
STUK trigger command.
S If LED2 is lit on ROI board PC10, a contactor signal is being sent from the robot.

P. Wire Feed Speed Error

ERR
Indicates actual wire feed speed does not match wire feed speed command. Press Jog/Purge button to clear error.
WFS

Q. Flow Error

ERR
Indicates no gas flow to the gun. The error may be reset by reestablishing gas flow to the gun, and then pressing the Jog/
Purge button.
FLOW

R. Stop Error

ERR
Indicates obstructions in the wire feed system or a faulty wire drive system. Check wire feed and wire drive systems.
Press Jog/Purge button to clear error.
STOP

OM-220 390 Page 35


S. Stuck Error

ERR
Indicates the welding wire is stuck to the workpiece at the end of a weld. May be caused by poor weld conditions. The
error may be cleared by cutting wire from workpiece, and pressing the Jog/Purge button.
STUK

T. Weld Wait Error

WELD
Indicates unit was not ready for a weld sequence. Press Jog/Purge button to clear error.
WAIT

U. Please Wait Error

PLS
Indicates user interface board lost data communications. Press Jog/Purge button to clear error. If condition persists, con-
tact nearest Factory Authorized Service gent.
WAIT

V. Low Wire Feed Speed Error

LOW
Indicates actual wire feed speed is lower than wire feed speed command. Check for obstructions in the wire feed system
or a faulty wire drive system. Press Jog/Purge button to clear error.
WFS

W. Robot Memory Error

ROBT
Indicates robot lost memory data. Press Jog/Purge button to clear error.
MEM

X. Unit Communication Error

UNIT
Indicates the data bus on the PCM board is not functioning properly. Press Jog/Purge button to clear error.
COMM

Y. RMD Done Message

RMD
Indicates the RMD demo is completed. Pressing Jog/Purge button will change the screen to CYCL PWR on the display.
Turn unit power off and back on again.
DONE

OM-220 390 Page 36


Z. Gas Flow Error

ERR
Indicates no gas flow to the gun. The error may be reset by re-establishing gas flow to the gun, and then pressing the Jog/
Purge button.
GAS

AA. Robot Communication Error

ROBT
The robot I/O module has lost communication with the welding power source. Contact factory service department for
assistance.
COMM

AB. Network Wait

NET
Indicates that the UIM board PC7 is no longer communicating with the PCM board PC4 by DeviceNet.
WAIT

AC. Cycle Power

CYCL
Request to cycle power from the welding power source. Turn unit power off and back on again.
PWR

AD. PCM Bus Communication

——
— — Indicates no error message on the displays. PCM board PC4 DeviceNet has gone offline. Turn welding power
source off and back on again to clear the communication error.
——

AE. RIO Bus Communication

——
— — Indicates no error message on the displays. RIO DeviceNet is losing packets of data. Turn welding power source off
and back on again to clear the communication error.
——

AF. Wire Feed Bus Communication

——
— — Indicates no error message on the displays. WFM board PC6 DeviceNet is losing packets of data. Turn welding
power source off and back on again to clear the communication error.
——

OM-220 390 Page 37


AG. UIM Bus Communication

——
— — Indicates no error message on the displays. UIM board PC7 DeviceNet is losing packets of data. Turn welding pow-
er source off and back on again to clear the communication error.
——

8-3. Troubleshooting

! Disconnect power before troubleshooting

Trouble Remedy

Wire feeds, shielding gas flows, but Check and secure weld cable connections (see Section 5-2).
electrode wire is not energized.

Electrode wire feeding stops or feeds Check gun trigger connection. See gun Owner’s Manual.
erratically during welding.
Check gun trigger. See gun Owner’s Manual.

Readjust hub tension and drive roll pressure (see Section 5-5).

Change to correct size drive roll (see 5-5).

Clean or replace dirty or worn drive roll.

Incorrect size or worn wire guides.

Replace contact tip or liner. See gun Owner’s Manual.

Remove weld spatter or foreign matter from around nozzle opening.

Have Factory Authorized Service Agency check drive motor or motor control board PC1.

Motor runs slowly. Check for correct input voltage.

Wire feeder power is on, displays light Check welding gun trigger leads for continuity, and repair leads or replace gun.
up, but unit is inoperative.

Notes

OM-220 390 Page 38


Notes

OM-220 390 Page 39


SECTION 9 − ELECTRICAL DIAGRAM

Figure 9-1. Circuit Diagram


OM-220 390 Page 40
211 005-G

OM-220 390 Page 41


SECTION 10 − PARTS LIST

. Hardware is common and


not available unless listed.

5
8
9
10
11
12
11
10
9

14

18

13

16
4 − Fig 10-3 17

15
23

19
1

20

21

22 − Fig
10-2

803 506-C

Figure 10-1. Main Assembly

OM-220 390 Page 42


Item Part
No. No. Description Quantity

Figure 10-1. Main Assembly

... 1 ............... 159 647 . . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 2 ............... 159 646 . . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 ............... 159 360 . . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 4 ............... Fig 10-3 . . 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 1.500 Dia x .125thk . . . . . . . . . . . . . . . . . . . . . . 2
... 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 ............... 248 974 . . . . Tubing, Stl .875 OD x 12 Ga Wall x .562 . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 ............... 135 205 . . . . Nut, Stl Slflkg Hex Reg .625-11 w/Nylon Insert . . . . . . . . . . . . . . . . . . . 1
... 15 ............... 200 556 . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 ............... 201 781 . . Knob, w/Extension Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 ............... 156 243 . . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 ............... 145 639 . . Strip, Buna N Compressed Sheet .062 x 4.000 x 4.000 . . . . . . . . . . . . . . 1
... 19 ............... 200 552 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 ............... 134 306 . . Foot, Rubber 1.250 Dia x 1.375 High No 10 Screw . . . . . . . . . . . . . . . . . 4
... 21 ............... 200 557 . . Stiffener, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 ............... Fig 10-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 ............... 216 695 . . Capacitor, w/Terminals (.027uf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
+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-220 390 Page 43


. Hardware is common and
not available unless listed.
2
1
7

5
9

4
23
3

10
6
14
15
12
13

22 16

17
18
11
19

20
21
803 507-F

Figure 10-2. Control Box

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 10-2. Control Box (Fig 10-1 Item 21)

. . . 1 . . . . . . . . . . . . . . . 238 487 .. Label, Warning General Precautionary (CE/Domestic) . . . . . . . . . . . . . . 1


. . . 2 . . . . . . . . . . . . . . +212 781 .. Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . *233 582 .. Panel, PC Card Switch/Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 212 808 .. Baffle, PC Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . PC6 . . . . . *239601 .. Circuit Card Assy, Wire Feed Module w/Program . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 236 991 .. Enclosure, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 010 494 .. Bushing, Snap−In Nyl 1.375 ID x 1.750 Mtg Hole . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 236 047 .. Bushing, Snap−In Nyl 1.750 ID x 2.000 Mtg Hole . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . RC1 . . . . . 211 018 .. Connector, Circ 97/Met 9 Pin Size 20 Rcpt . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG43,46,49,
72 . . . . . . 115 093 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 220 805 . . Nut, 750-14 NPS 1.48hex .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 228 035 . . Valve, 34VDC 1way .750−14thd 2mm Orf 100psi . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 134 201 . . Stand−Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 13 . . . . . . . . . . . . . . . 097 132 . . Stand−Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 14 . . . . . . . . . . . . . . . 236 979 . . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC2 . . . . . 242362 . . Circuit Card Assy, Motor Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . S1 . . . . . . 213 632 . . Switch, Rocker DPDT 10A 250VAC/20A 30VAC On-None-On . . . . . . . . 1
. . . 17 . . . . PC1 . . . . . 242360 . . Circuit Card Assy, Trigger Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
+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-220 390 Page 44


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-2. Control Box (Fig 10-1 Item 21) (Continued)

. . . 18 . . . . RC4 . . . . . 048 282 . . Rcpt w/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 19 . . . . . . . . . . . . . . . 211 085 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 211 073 . . Nameplate, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 210 998 . . Switch Assy, Jog/Purge (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . S2 . . . . . . 200 295 . . . . Switch, Rocker SPDT 15A 12V (On)-Off-(On) . . . . . . . . . . . . . . . . . . . . 1
..................... 131 056 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 131 052 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 179 851 . . Knob, Pointer 1.670 Dia x .250 ID Push On W/Spring . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 216 866 . . Filter Assy, Sense Lead (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 216 696 . . . . Capacitor, w/Terminals (.027uf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 038 855 . . . . Block, Term 20 Amp 2 Pole Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 224 383 . . . . Resistor, w/Terminals (2k 5 watt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 216 872 . . . . Cable, Volt Sense 7 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 213 004 . . . . Cable, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG47 . . . . 115 094 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG48 . . . . 202 592 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . . 136 810 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG81 . . . . 115 092 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . . 130 203 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG50 . . . . 136 810 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG44 . . . . 131 058 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG45 . . . . 188 352 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG42 . . . . 131 054 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG40 . . . . 201 665 . . Housing Rcpt Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 098 691 . . Stand−Off, No 6-32 x .500 Lg .250 Hex Stl M&F . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
+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-220 390 Page 45


. Hardware is common and
not available unless listed. 11
12
13
14
See Table 10-1 For 15
Drive Roll & Wire Guide Kits 16
17
18
9
6 7 8
4 5
3 12
2
1 19
10
13

31
20

21
22
23
30
25 24
33
26
29 6
32 5
28 27 4
3
2
1
802 950−D

Figure 10-3. Drive Assembly, Wire


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-3. Drive Assembly, Wire (Fig 10-1 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 . . . . . *213 005 . . Motor, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 203 631 . . Pressure Arm (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 182 415 . . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 203 640 . . . . Knob, w/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 203 641 . . . . Washer, Flat Stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . . 182 156 . . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . . 182 155 . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . . 132 746 . . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . . 203 633 . . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 203 632 . . . . Carrier, Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 133 739 . . . . Washer, Flat Buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 203 637 . . . . Knob, W/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . {Encoder Assy, Quad 500 CPR 5 VDC Shaftless w/Plug (including) . . . 1
. . . . . . . . . . . . . . . . . . . . . 261 292 . . . . Encoder, Differential E8p 500cpr 1/4” Bore . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 261 293 . . . . Cbl Assy, Shielded 4 Wire 18” Axcess Encoder w/Plug . . . . . . . . . . . . . 1
*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.
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-220 390 Page 46
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-3. Drive Assembly, Wire (Fig 10-1 Item 4) (continued)

. . . 21 . . . . . . . . . . . . . . . 167 387 . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


. . . 22 . . . . . . . . . . . . . . . 168 825 . . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 133 308 . . Ring, Retaining Ext .375 Shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 134 834 . . Hose, SAE .187 ID x .410 OD (Order By ft) . . . . . . . . . . . . . . . . . . . . . . . . 2ft
..................... 184 685 . . Adapter Assy, Gun/Feeder LH (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 149 959 . . . . Fitting, Brs Barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 179 265 . . . . Adapter, Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 604 538 . . . . Washer, Flat Stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 151 437 . . . . Knob, Plstc T 1.125 Lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 185 624 . . . . Screw, 010-32 x O.50 Hexwhd .40d Stl Pld Slffmg Trilob . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . . . 167 788 . . . . Nut, 375-16 .56 hex .34h Stl Pld Sem Cone Wshr .88d . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 601 966 . . . . Screw, Cap Stl Hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 108 940 . . Screw, Cap Stl Hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . . . . . . . . . . . 179 263 . . Cover, Drive Roll (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 178 937 . . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.
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-220 390 Page 47


”V” GROOVE FOR ”U” GROOVE FOR ”V” KNURLED FOR ”U” COGGED FOR ”U” GROOVE FOR
HARD WIRE SOFTSHELLED HARDSHELLED EXTREMELY SOFT ALUMINUM WIRES
CORED WIRES CORED WIRES WIRE OR SOFT CONTAINS NYLON
WIRE GUIDES

OM-220 390 Page 48


SHELLED CORED
WIRES

WIRE SIZE
.023/.025 in. (0.6 mm) 151024
.030 in. (0.8 mm) 151025
.035 in. (0.9 mm) 151026 151052 243233
.040 in. (1.0 mm) 161190
.045 in. (1.1/1.2 mm) 151027 151037* 151053 151070 243234*
.052 in. (1.3/1.4 mm) 151028 151038 151054 151071
1/16 in. (1.6 mm) 151029 151039 151055 151072 243235
.068/.072 in. (1.8 mm) 151056
5/64 in. (2.0 mm) 151040 151057 151073
3/32 in. (2.4 mm) 151041 151058 151074
7/64 in. (2.8 mm) 151042 151059 151075
1/8 in. (3.2 mm) 151043** 151060** 151076**
Table 10-1. Drive Roll And Wire Guide Kits

*Accommodates .045 and .047 (3/64 in) wire


**Requires a low speed wire feeder

Wire Guides Nylon Wire Guides for Feeding Aluminum Wire


Wire Sizes Inlet Guide Intermediate Guide Wire Size Inlet Guide Intermediate Guide
.023 to .040 in. (0.6 to 1.0mm) 221030 149518 .035 in. (0.9mm) 221912 242417
.045 to .052 in. (1.1 to 1.4mm) 221030 149519 .047 in. (1.2mm) 221912 205936
1/16 to 5/64 in. (1.6 to 2mm) 221030 149520 1/16 in. (1.6mm) 221912 205937
3/32 to 7/64 in. (2.4 to 2.8mm) 229919 149521
1/8 in. (3.2mm) 229919 149522
Notes
Notes
Effective January 1, 2014
(Equipment with a serial number preface of ME or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
for your local workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace Non-Electronic Controls
Your distributor also gives any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Guns
Service provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
You always get the fast, followed. * Replacement Parts (No labor)
reliable response you * Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed * Spoolmate Spoolguns
need. Most replacement below in the event of such a failure within the warranty time periods.
parts can be in your Miller’s True Blue Limited Warranty shall not apply to:
All warranty time periods start on the delivery date of the equipment
hands in 24 hours. to the original end-user purchaser, and not to exceed twelve months 1. Consumable components; such as contact tips,
after the equipment is shipped to a North American distributor or cutting nozzles, contactors, brushes, relays, work
Support eighteen months after the equipment is shipped to an International station table tops and welding curtains, or parts that
Need fast answers to the distributor. fail due to normal wear. (Exception: brushes and
tough welding questions? relays are covered on all engine-driven products.)
Contact your distributor. 1. 5 Years Parts — 3 Years Labor
2. Items furnished by Miller, but manufactured by others,
The expertise of the * Original Main Power Rectifiers Only to Include SCRs, such as engines or trade accessories. These items are
distributor and Miller is Diodes, and Discrete Rectifier Modules covered by the manufacturer’s warranty, if any.
there to help you, every 2. 3 Years — Parts and Labor 3. Equipment that has been modified by any party other than
step of the way. * Auto-Darkening Helmet Lenses (Except Classic Miller, or equipment that has been improperly installed,
Series) (No Labor) improperly operated or misused based upon industry
* Engine Driven Welding Generators standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the and necessary maintenance, or equipment which has
Engine Manufacturer.) been used for operation outside of the specifications for
* Inverter Power Sources (Unless Otherwise Stated) the equipment.
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Process Controllers TRAINED AND EXPERIENCED IN THE USE AND
* Semi-Automatic and Automatic Wire Feeders MAINTENANCE OF WELDING EQUIPMENT.
* Transformer/Rectifier Power Sources In the event of a warranty claim covered by this warranty, the
3. 2 Years — Parts and Labor exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
* Auto-Darkening Helmet Lenses − Classic Series Only cases, (3) the reasonable cost of repair or replacement at an
(No Labor) authorized Miller service station; or (4) payment of or credit for the
* Fume Extractors − Capture 5, Filtair 400 and Industrial purchase price (less reasonable depreciation based upon actual
Collector Series use) upon return of the goods at customer’s risk and expense.
4. 1 Year — Parts and Labor Unless Specified 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
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
* CoolBelt and CoolBand Blower Unit (No Labor) reimbursement for transportation costs of any kind will be allowed.
* External Monitoring Equipment and Sensors TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Field Options PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
(NOTE: Field options are covered for the remaining
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, or CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
for a minimum of one year — whichever is greater.) WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
* RFCS Foot Controls (Except RFCS-RJ45) LEGAL THEORY.
* Fume Extractors − Filtair 130, MWX and SWX Series ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* HF Units IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* ICE/XT Plasma Cutting Torches (No Labor) CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* Induction Heating Power Sources, Coolers BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
(NOTE: Digital Recorders are Warranted Separately OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
by the Manufacturer.) DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* LiveArc Welding Performance Management System MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Load Banks
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Motor Driven Guns (except Spoolmate Spoolguns) MILLER.
* PAPR Blower Unit (No Labor) Some states in the U.S.A. do not allow limitations of how long an
* Positioners and Controllers implied warranty lasts, or the exclusion of incidental, indirect,
* Racks special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
* Water Coolant Systems additional warranties or remedies other than as stated herein, and to
* TIG Torches (No Labor) the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2014-04-14
Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
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.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

ORIGINAL INSTRUCTIONS − PRINTED IN USA  2014 Miller Electric Mfg. Co. 2014−01

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