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Processes
Description
Arc Welding Power Source
and Wire Feeder
OM-1322 200 070M
October 2003
Visit our website at
www.MillerWelds.com
Millermatic PulserM-15 Gun And Spoolmate
3035 Spool Gun
�
Flux Cored (FCAW) Welding
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you don’t have time to doit 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 superiorquality. Like you, his customers couldn’t afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.
Today, the people that build and sell Miller products continue thetradition. They’re just as committed to providing equipment and servicethat 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 yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,there’s a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.
Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.
Working as hard as you do− every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.
� Marks a special safety message.
� Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.
1-2. Arc Welding Hazards
� The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, a nd follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.
� Only qualified persons should install, operate, maintain, andrepair this unit.
� During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.
� Do not touch live electrical parts.
� Wear dry, hole-free insulating gloves and body protection.
� Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.
� Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.
� Use AC output ONLY if required for the welding process.
� If AC output is required, use remote output control if present onunit.
� Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).
� Properly install and ground this equipment according to itsOwner’s Manual and national, state, and local codes.
� Always verify the supply ground − check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.
� When making input connections, attach proper grounding conduc-tor first − double-check connections.
� Frequently inspect input power cord for damage or bare wiring −replace cord immediately if damaged − bare wiring can kill.
� Turn off all equipment when not in use.
� Do not use worn, damaged, undersized, or poorly spliced cables.
� Do not drape cables over your body.
� If earth grounding of the workpiece is required, ground it directlywith a separate cable.
� Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.
� Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.
� Wear a safety harness if working above floor level.
� Keep all panels and covers securely in place.
� Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.
� Insulate work clamp when not connected to workpiece to preventcontact with any metal object.
� Do not connect more than one electrode or work cable to anysingle weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters.� Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Sectionbefore touching any parts.
Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.
FUMES AND GASES can be hazardous.
� Keep your head out of the fumes. Do not breathe the fumes.
� If inside, ventilate the area and/or use exhaust at the arc to removewelding fumes and gases.
� If ventilation is poor, use an approved air-supplied respirator.
� Read the Material Safety Data Sheets (MSDSs) and themanufacturer’s instructions for metals, consumables, coatings,cleaners, and degreasers.
� Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.
� Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.
� Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.
OM-1322 Page 2 Return To Table Of Contents
Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.
ARC RAYS can burn eyes and skin.
� Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).
� Wear approved safety glasses with side shields under yourhelmet.
� Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.
� Wear protective clothing made from durable, flame-resistant mate-rial (leather and wool) and foot protection.
Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.
WELDING can cause fire or explosion.
� Protect yourself and others from flying sparks and hot metal.
� Do not weld where flying sparks can strike flammable material.
� Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.
� Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.
� Watch for fire, and keep a fire extinguisher nearby.
� Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.
� Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).
� Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock and fire hazards.
� Do not use welder to thaw frozen pipes.
� Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.
� Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.
� Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.
FLYING METAL can injure eyes.
� Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.
� Wear approved safety glasses with sideshields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
� Shut off shielding gas supply when not in use.� Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
� Do not touch hot parts bare handed.� Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
� Pacemaker wearers keep away.� Wearers should consult their doctor before
going near arc welding, gouging, or spotwelding operations.
NOISE can damage hearing.
Noise from some processes or equipment candamage hearing.
� Wear approved ear protection if noise level ishigh.
Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.
CYLINDERS can explode if damaged.
� Protect compressed gas cylinders from excessive heat, mechani-cal shocks, slag, open flames, sparks, and arcs.
� Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.
� Keep cylinders away from any welding or other electrical circuits.
� Never drape a welding torch over a gas cylinder.
� Never allow a welding electrode to touch any cylinder.
� Never weld on a pressurized cylinder − explosion will result.
� Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.
� Turn face away from valve outlet when opening cylinder valve.
� Keep protective cap in place over valve except when cylinder is inuse or connected for use.
� Read and follow instructions on compressed gas cylinders,associated equipment, and CGA publication P-1 listed in SafetyStandards.
OM-1322 Page 3Return To Table Of Contents
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
� Do not install or place unit on, over, or nearcombustible surfaces.
� Do not install unit near flammables.
� Do not overload building wiring − be sure power supply system isproperly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
� Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.
� Use equipment of adequate capacity to lift andsupport unit.
� If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.
OVERUSE can cause OVERHEATING
� Allow cooling period; follow rated duty cycle.� Reduce current or reduce duty cycle before
starting to weld again.� Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
� Put on grounded wrist strap BEFORE handlingboards or parts.
� Use proper static-proof bags and boxes tostore, move, or ship PC boards.
MOVING PARTS can cause injury.
� Keep away from moving parts.� Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
� Do not press gun trigger until instructed to doso.
� Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.
MOVING PARTS can cause injury.
� Keep away from moving parts such as fans.� Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
� High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.
� Have only qualified persons familiar withelectronic equipment perform this installation.
� The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.
� If notified by the FCC about interference, stop using theequipment at once.
� Have the installation regularly checked and maintained.
� Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.
ARC WELDING can cause interference.
� Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.
� Be sure all equipment in the welding area iselectromagnetically compatible.
� To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.
� Locate welding operation 100 meters from any sensitive elec-tronic equipment.
� Be sure this welding machine is installed and groundedaccording to this manual.
� If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
� Welding or cutting equipment produces fumes or gases whichcontain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &Safety Code Section 25249.5 et seq.)
� Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.
For Gasoline Engines:� Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductiveharm.
For Diesel Engines:� Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, andother reproductive harm.
OM-1322 Page 4 Return To Table Of Contents
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-site: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-ternational.org).
Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, from American National Standards Institute, 11West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:617−770−3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (thereare 10 Regional Offices−−phone for Region 5, Chicago, is312−353−2220, website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: “The body of evidence, in thecommittee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.”However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-ble.
About Pacemakers:Pacemaker wearers consult your doctor first. If cleared by your doctor,then following the above procedures is recommended.
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SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANTUTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »Cette procédure présente des risques identifiés par lessymboles adjacents aux directives.
� Identifie un message de sécurité particulier.
� Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi-lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, auxPIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporteraux symboles et aux directives ci-dessous afin de connaître les me-sures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
� Les symboles ci-après sont utilisés tout au long du présentmanuel pour attirer l’attention sur les dangers potentiels et lesidentifier. Lorsqu’on voit un symbole, faire preuve de vigilance etsuivre les directives mentionnées afin d’éviter tout danger. Lesconsignes de sécurité énoncées ci-après ne font que résumer lecontenu des normes de sécurité mentionnées à la section 2-4.Lire et respecter toutes ces normes.
� L’installation, l’utilisation, l’entretien et les réparations ne doi-vent être confiés qu’à des personnes qualifiées.
� Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,en particulier les enfants.
LES DÉCHARGES ÉLECTRIQUESpeuvent être mortelles.Un simple contact avec des pièces sous tension peutcauser une électrocution ou des blessures graves.L’électrode et le circuit de soudage sont sous tensiondès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.En soudage semi−automatique ou automatique, le fil, le dévidoir, lelogement des galets d’entraînement et les pièces métalliques en contactavec le fil de soudage sont sous tension. Tout matériel mal installé ou malmis à la terre présente un danger.
� Ne jamais toucher aux pièces électriques sous tension.� Porter des gants et des vêtements de protection secs et exempts de
trous.� S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi-
tifs isolants suffisamment grands pour empêcher tout contactphysique avec la pièce ou la terre.
� Ne pas se servir d’une source de courant alternatif dans les zones humi-des, les endroits confinés ou là où on risque de tomber.
� Ne se servir d’une source de courant alternatif QUE si le procédé de souda-ge l’exige.
� Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser-vir de la fonction de télécommande si l’appareil en est équipé.
� Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueterl’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor-mes de sécurité).
� Installer et mettre à la terre correctement l’appareil conformément àson manuel d’utilisation et aux codes nationaux, provinciaux etmunicipaux.
� Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assu-rer que le fil de terre du cordon d’alimentation est bien raccordé à laborne de terre du sectionneur ou que la fiche du cordon est raccordéeà une prise correctement mise à la terre.
� Pour exécuter les branchements d’entrée, fixer d’abord le conducteurde mise à la terre adéquat et contre−vérifier les connexions.
� Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’estni endommagé ni dénudé ; le remplacer immédiatement s’il est en-dommagé − tout câble dénudé peut causer une électrocution.
� Mettre l’appareil hors tension quand on ne l’utilise pas.� Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.� Ne pas s’enrouler les câbles autour du corps.� Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.� Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
� N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−champ les pièces endommagées. Entretenir l’appareil conformémentau présent manuel.
� Porter un harnais de sécurité quand on travaille en hauteur.
� Maintenir solidement en place tous les panneaux et capots.
� Fixer le câble de retour de façon à obtenir un bon contact métal surmétal avec la pièce à souder ou la table de travail, le plus près possiblede la soudure.
� Ne pas connecter plus d’une électrode ou plus d’un câble de masse à unmême terminal de sortie.
Il subsiste un COURANT CONTINU IMPORTANTdans les convertisseurs après la suppression del’alimentation électrique.� Arrêter les convertisseurs, débrancher le courant électrique et dé-
charger les condensateurs d’alimentation selon les instructionsénoncées à la section Entretien avant de toucher les pièces.
Le soudage génère des fumées et des gaz dontl’inhalation peut être dangereuse pour la santé.
LES FUMÉES ET LES GAZ peuventêtre dangereux.
� Se tenir à distance des fumées et ne pas les inhaler.
� À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration auniveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
� Si la ventilation est insuffisante, utiliser un respirateur à adductiond’air agréé.
� Lire les fiches techniques de santé−sécurité (FTSS) et les instruc-tions du fabricant concernant les métaux, les consommables, lesrevêtements, les nettoyants et les dégraisseurs.
� Ne travailler dans un espace clos que s’il est bien ventilé ou porter unrespirateur à adduction d’air. Demander toujours à un surveillant dû-ment formé de se tenir à proximité. Des fumées et des gaz de soudagepeuvent se substituer à l’air, abaisser la teneur en oxygène et causerdes lésions ou des accidents mortels. S’assurer que l’air est respira-ble.
� Ne pas souder à proximité d’opérations de dégraissage, de nettoyageou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir enprésence de vapeurs et former des gaz hautement toxiques et irri-tants.
� Ne pas souder de métaux munis d’un revêtement, tels que la tôled’acier galvanisée, plombée ou cadmiée, à moins que le revêtementn’ait été enlevé dans la zone de soudage, que l’endroit soit bien venti-lé, et si nécessaire, porter un respirateur à adduction d’air. Lesrevêtements et tous les métaux renfermant ces éléments peuvent dé-gager des fumées toxiques lorsqu’on les soude.
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Le rayonnement de l’arc génère des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des brûlures oculaires et cutanées.Des étincelles sont projetées pendant le soudage.
LES RAYONS DE L’ARC peuvent cau-ser des brûlures oculaires et cuta-nées.
� Porter un masque de soudage muni d’un filtre de la nuance adéquatepour se protéger le visage et les yeux pendant le soudage ou pour re-garder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
� Porter des lunettes de sécurité à écrans latéraux sous le masque.� Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarderl’arc.
� Porter des vêtements de protection en matière durable et ignifuge(cuir ou laine) et des chaussures de sécurité.
Le soudage effectué sur des récipients fermés tels quedes réservoirs, des fûts ou des conduites peut causerleur éclatement. Des étincelles peuvent être projetéesde l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer desincendies et des brûlures. Le contact accidentel de l’électrode avec toutobjet métallique peut causer des étincelles, une explosion, un surchauf-fement ou un incendie. Avant de commencer le soudage, vérifier ets’assurer que l’endroit ne présente pas de danger.
LE SOUDAGE peut causer un incen-die ou une explosion.
� Se protéger et protéger les tiers de la projection d’étincelles et de mé-tal chaud.
� Ne pas souder à un endroit où des étincelles peuvent tomber sur dessubstances inflammables.
� Placer toutes les substances inflammables à une distance de 10,7 mde l’arc de soudage. En cas d’impossibilité, les recouvrir soigneuse-ment avec des protections agréées.
� Des étincelles et des matières en fusion peuvent facilement passermême par des fissures et des ouvertures de petites dimensions.
� Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-mité.
� Le soudage effectué sur un plafond, un plancher, une paroi ou unecloison peut déclencher un incendie de l’autre côté.
� Ne pas souder des récipients fermés tels que des réservoirs, des fûtsou des conduites, à moins qu’ils n’aient été préparés conformément àl’AWS F4.1 (voir les normes de sécurité).
� Brancher le câble sur la pièce le plus près possible de la zone de sou-dage pour éviter que le courant ne circule sur une longue distance, pardes chemins inconnus, et ne cause des risques d’électrocution et d’in-cendie.
� Ne pas utiliser le poste de soudage pour dégeler des conduites ge-lées.
� En cas de non utilisation, enlever la baguette d’électrode du porte−électrode ou couper le fil au raz du tube−contact.
� Porter des vêtements de protection exempts d’huile tels que desgants en cuir, une chemise en tissu épais, des pantalons sans revers,des chaussures montantes et un masque.
� Avant de souder, retirer tout produit combustible de ses poches, telqu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peu-vent blesser les yeux.
� Le soudage, le burinage, le passage de la pièce àla brosse métallique et le meulage provoquentl’émission d’étincelles et de particules métalli-
ques. Pendant leur refroidissement, les soudures risquent de projeter dulaitier.� Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
LES ACCUMULATIONS DE GAZ peu-vent causer des blessures ou mêmela mort.
� Couper l’alimentation en gaz protecteur en cas denon utilisation.
� Veiller toujours à bien ventiler les espaces confinés ou porter un respira-teur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent cau-ser des brûlures graves.
� Ne pas toucher les pièces chaudes à main nue.� Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuventperturber le fonctionnement des stimu-lateurs cardiaques.
� Les personnes qui portent un stimulateur cardiaquedoivent se tenir à distance.
� Ils doivent consulter leur médecin avant de s’appro-cher d’un lieu où on exécute des opérations de sou-dage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peutaffecter l’ouïe.
� Porter des protecteurs d’oreille agréés si le niveausonore est trop élevé.
Les bouteilles de gaz protecteur contiennent du gazsous haute pression. Toute bouteille endommagéepeut exploser. Comme les bouteilles de gaz fontnormalement partie du procédé de soudage, les
manipuler avec précaution.
Les BOUTEILLES endommagéespeuvent exploser.
� Protéger les bouteilles de gaz comprimé de la chaleur excessive, deschocs mécaniques, du laitier, des flammes nues, des étincelles et desarcs.
� Placer les bouteilles debout en les fixant dans un support stationnaireou dans un porte−bouteilles pour les empêcher de tomber ou de serenverser.
� Tenir les bouteilles éloignées des circuits de soudage ou autres cir-cuits électriques.
� Ne jamais poser une torche de soudage sur une bouteille de gaz.� Ne jamais mettre une électrode de soudage en contact avec une bou-
teille de gaz.� Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.� N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bonétat, ainsi que les pièces connexes.
� Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.� Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-
tion ou de branchement de la bouteille� Lire et suivre les instructions concernant les bouteilles de gaz compri-
mé, les équipements associés et les publications P−1 de la CGA,mentionnées dans les normes de sécurité.
OM-1322 Page 7Revenez à la table des matières
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien del’appareil.
Risque D’INCENDIE OU D’EXPLO-SION
� Ne pas placer l’appareil sur une surface inflam-mable, ni au−dessus ou à proximité d’elle.
� Ne pas installer l’appareil à proximité de produits inflammables.� Ne pas surcharger l’installation électrique − s’assurer que l’alimen-
tation est correctement dimensionnée et protégée avant de mettrel’appareil en service.
LA CHUTE DE L’APPAREIL peutblesser.
� N’utiliser que l’anneau de levage pour lever l’ap-pareil. NE PAS utiliser le chariot, les bouteilles degaz ou tout autre accessoire.
� Utiliser un engin de capacité adéquate pour leverl’appareil.
� Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer queles fourches sont suffisamment longues pour dépasser du côté op-posé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRESURCHAUFFER L’ÉQUIPEMENT.
� Prévoir une période de refroidissement ; respec-ter le cycle opératoire nominal.
� Réduire le courant ou le cycle opératoire avant dereprendre le soudage.
� Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATI-QUES peuvent endommager les cir-cuits imprimés.
� Mettre un bracelet antistatique AVANT de mani-puler des cartes ou des pièces.
� Utiliser des pochettes et des boîtes antistatiquespour stocker, déplacer ou expédier des cartes decircuits imprimés.
LES PIÈCES MOBILES peuvent cau-ser des blessures.
� Se tenir à l’écart des pièces mobiles.� Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent cau-ser des blessures.
� Ne pas appuyer sur la gâchette avant d’en avoirreçu l’instruction.
� Ne pas diriger le pistolet vers soi, vers d’autrespersonnes ou vers toute pièce mécanique en en-gageant le fil de soudage.
LES ORGANES MOBILES peuventcauser des blessures.
� Se tenir à l’écart des organes mobiles comme lesventilateurs.
� Maintenir fermés et bien fixés les portes,panneaux, recouvrements et dispositifs deprotection.
LE RAYONNEMENT HAUTE FRÉ-QUENCE (H. F.) risque de causer desinterférences.
� Le rayonnement haute fréquence peut causerdes interférences avec les équipements de radio-navigation et de communication, les services desécurité et les ordinateurs.
� Ne demander qu’à des personnes qualifiées familiarisées avec leséquipements électroniques de faire fonctionner l’installation.
� L’utilisateur est tenu de faire corriger rapidement par un électricienqualifié les interférences causées par l’installation.
� Si la Federal Communications Commission signale des interféren-ces, arrêter immédiatement l’appareil.
� Faire régulièrement contrôler et entretenir l’installation.� Maintenir soigneusement fermés les panneaux et les portes des sour-
ces de haute fréquence, maintenir le jeu d’éclatement au réglageadéquat et utiliser une terre et un blindage pour réduire les interféren-ces éventuelles.
LE SOUDAGE À L’ARC peut causerdes interférences.
� L’énergie électromagnétique peut causer desinterférences avec l’équipement électroniquesensible tel que les ordinateurs et l’équipementcommandé par ordinateur tel que les robots.
� Veiller à ce que tout l’équipement de la zone de soudage soit compati-ble au point de vue électromagnétique.
� Pour réduire la possibilité d’interférence, maintenir les câbles de sou-dage aussi courts que possible, les grouper, et les poser aussi basque possible (par ex. : à terre).
� Veiller à souder à une distance de 100 mètres de tout équipementélectronique sensible.
� Veiller à ce que le poste de soudage soit posé et mis à la terre confor-mément au présent manuel.
� En cas d’interférences après exécution des directives précédentes, ilincombe à l’utilisateur de prendre des mesures supplémentaires tel-les que le déplacement du poste, l’utilisation de câbles blindés,l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone detravail.
LES CHAMPS MAGNÉTIQUES peuventaffecter les stimulateurs cardiaques.
� Porteurs de stimulateur cardiaque, restez à dis-tance.
� Les porteurs d’un stimulateur cardiaque doiventd’abord consulter leur médecin avant de s’appro-cher des opérations de soudage à l’arc, de gou-geage ou de soudage par points.
OM-1322 Page 8 Revenez à la table des matières
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(téléphone : (305) 443−9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, norme American Welding Society AWSF4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire ProtectionAssociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org etwww.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,de la Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca-nadian Standards Association, Standards Sales, 178 boulevard
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna-tional.org).
Practice For Occupational And Educational Eye And Face Protection,norme ANSI Z87.1, de l’American National Standards Institute, 11 West42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,site Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other HotWork, norme NFPA 51B, de la National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé-phone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, de l’U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnéti-ques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs élec-tromagnétiques. Les effets potentiels de tels champs restentpréoccupants. Cependant, après avoir examiné plus de 500 études quiont été faites pendant une période de recherche de 17 ans, un comitéde spécialistes du National Research Council a conclu : « L’accumula-tion de preuves n’a pas démontré que l’exposition aux champsmagnétiques et aux champs électriques à haute fréquence constitue unrisque pour la santé humaine ». Toutefois, les études et l’examen despreuves se poursuivent. En attendant les conclusions finales de la re-cherche, il serait souhaitable de réduire l’exposition aux champsélectromagnétiques pendant le soudage ou le coupage.
Afin de réduire les champs électromagnétiques en milieu de travail, res-pecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec duruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-mandé de respecter les consignes ci-dessus.
OM-1322 Page 9Return To Table Of Contents
SECTION 3 − INSTALLATION
3-1. Welding Power Source And MIG Gun Specifications
Rated Output AmperageMax. Open
CircuitAmps Input at Rated Output, 50 or 60 Hz, Single-Phase
Rated Output AmperageRange DC
CircuitVoltage DC 200 (208) V 230 V 240 V 460 575 KVA KW
Operating Temperature Range − −20C to +40C Storage Temperature Range − -30C to + 50C
3-2. Spool Gun Specifications
Wire Diameter RangeApproximate Wire
Feed RangeCoolingMethod
Maximum SpoolSize Overall Dimensions Weight
.023 Thru .035 in(0.6 Thru 0.9 mm)
Aluminum Wire
.023 Thru 035 in(0.6 Thru 0.9 mm) Hard
Or Cored Wire
115 To 715 ipm (4.1To 20.4 mpm) Air Cooled
4 in (102 mm)Diameter
Length: 11-1/2 in (291 mm)
Width:2-1/4 in (57 mm)
Height:8 in (203 mm)
9.1 lb (4.1 kg)Gun With Cable
OM-1322 Page 10 Return To Table Of Contents
3-3. Welding Power Source Duty Cycle And Overheating
6 Minutes Welding 4 Minutes Resting
Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.
If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orvoltage, or duty cycle beforewelding.
� Exceeding duty cycle candamage unit and voidwarranty.
Overheating
0
15
A or V
ORReduce Duty Cycle
Minutes
duty1 4/95 − 200 060
30% Duty Cycle At 200 Amperes60% Duty Cycle At 160 Amperes
3 Minutes Welding 7 Minutes Resting
3-4. MIG Welding Gun Duty Cycle And Overheating
CAUTIONWELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.• Do not weld at rated load longer than shown below.
Block front casters to prevent movement.Block up rear of unit.
2 Dual Cylinder Support Bracket
3 Chain
Install supplied chains onto dual bracket.
4 Dual Cylinder Rack
5 Axle
6 Wheel
7 Washer
8 Retaining Ring
Install axle, wheel, washer, and retainingring to both sides as shown.
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3-8. Installing Work Clamp
1 Work Cable
2 Boot
Route cable through front panelopening. Slide boot onto workcable.
3 Negative (−) Output Terminal
Connect cable to terminal andcover connection with boot.
Close door.
802 713-B
Tools Needed:
1/2, 3/4 in
3
2 1
MIG PULSE203006
+ +−
3-9. Installing MIG Welding Gun
1 Drive Assembly
2 Gun Securing Knob
3 Gun End
Loosen securing knob. Insert gunend through opening until it bottomsagainst drive assembly (make suregun end does not touch drive rolls).Tighten knob.
4 Gun Trigger Plug
Insert plug into receptacle labeled“MIG GUN”, and tighten threadedcollar.
Close door.
Ref. 802 714-B
1
3
4
2
OM-1322 Page 14 Return To Table Of Contents
3-10. Connecting A Spool Gun
1 Barbed Fitting
� If spool gun gas hose isequipped with a pre-installedbarbed fitting, cut off fitting fromend of hose.
Connect spool gun gas hose tobarbed fitting.
2 Pulse Weld Terminal
Connect spool gun cable to pulseweld terminal.
3 Gun Trigger Plug
Insert plug into receptacle labeled“SPOOL GUN”, and tightenthreaded collar.
4 Negative (−) Output Terminal
5 Positive (+) Output Terminal(Non-Pulsing)
Close door.
2
45
802 710-C
13
3-11. Setting MIG Gun Polarity For Wire Type
1 Polarity Changeover Information
Always read and follow wiremanufacture’s recommended polarity.
� If the spool gun and standard MIGgun are both connected to themachine, both welding wires willbecome energized by pullingeither gun trigger. Welding wirewill only feed from the gun that thetrigger is pulled and only one gunat a time can be used for welding.
1
3/4 inRef. 190 821-A
Shown As Shipped − Set For Electrode Positive (DCEP) forSolid Steel, Stainless Steel, Aluminum or Gas Shielded FluxCore Wires.
Wire Drive AssemblyLead To Positive (+)
Output Terminal
Work Clamp LeadTo Negative (−)
Output Terminal
Spool Gun Lead ToPositive (+) PulseOutput Terminal
Reverse MIG Lead Connections − Set for Electrode Negative(DCEN). For Gasless Flux Cored Wires (FCAW Process).Drive Assembly Becomes Negative.
OM-1322 Page 15Return To Table Of Contents
3-12. Installing Gas Supply
802 028-A / Ref. 802 717-C / 201 022
Tools Needed:
Obtain gas cylinders and chain torunning gear, wall, or otherstationary support so cylinderscannot fall and break off valve.
1 Cap
2 Cylinder Valve
Remove cap, stand to side ofvalve, and open valve slightly. Gasflow blows dust and dirt from valve.Close valve.
3 Cylinder
4 Regulator/Flowmeter (2)
Install so face is vertical.
5 Regulator/Flowmeter GasHose Connection
6 Welding Power Source GasHose Connection For SpoolGun
7 Welding Power Source GasHose Connection For MIGGun
Connect gas hoses betweenregulator/flowmeter gas hoseconnections, and fittings on rear ofwelding power source.
8 Gas Flow Adjustment Control
Typical flow rate is 20 cfh (cubicfeet per hour). Check wiremanufacturer’s recommendedflow rate.
1-1/8, 5/8 in
4
5
8
1
2
3
6
7
RearPanel
Argon Gas OrMixed Gas
�DO NOT use Argon/Mixed gas regulator/flowmeterwith CO2 shielding gas. See Parts List for optionalCO2 gas regulator/flowmeter.
OM-1322 Page 16 Return To Table Of Contents
3-13. Installing MIG Wire Spool and Adjusting Hub Tension
ST-072573-B
When a slight force is needed to turn spool, tension is set.
15/16 in
Use compression spring with8 in (200 mm) spools.
Tools Needed:
OM-1322 Page 17Return To Table Of Contents
3-14. Installing Spool Gun Wire Spool And Threading Welding Wire
Ref. 801 891-A
Tools Needed:
1 Thumb Screw
2 Spool Cover
Remove thumb screw and spoolcover.
3 Hub Tension Nut
4 Wire Spool
Install spool so wire feeds from top.Turn hub tension nut just so a slightdrag is felt on the wire spool.
5 Push Roll/Lower Drive Roll
6 Drive Roll PressureAdjustment Opening
7 Drive Roll Release Lever(Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle
4
1
5
6 7 8
10
9
3
Remove nozzle and contact tip. Pushand hold red lever. Thread wire throughinlet guide, past push roll/drive roll, andout end of gun 2 inches (50 mm).
Release red lever.
Turn On weldingpower source power.
Install contact tip and nozzle. Reinstallspool cover and thumb screw.
Wood
Cut off wire.Press gun trigger to feed wire to check drive rollpressure. Turn screw enough to prevent slipping.
2
�Screw rotation clockwise decreasesdrive roll pressure and counterclockwiserotation increases pressure.
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3-15. Positioning Jumper Links
Ref. 802 714-B
Check input voltage available atsite and listed on the machine ratinglabel.
1 Jumper Links Access Door
Open door.
2 Jumper Link Label
Check label − only one is on unit.
3 Input Voltage Jumper Links
Move jumper links to match inputvoltage.
Close and secure access door.
Tools Needed:
1
3/8 in
3
2
200 VOL TS
230 VOL TS
240 VOL TS
203529
�Before setting jumper link, check input voltage and linkunit for voltage closest to the input voltage at the site.
3
3-16. Electrical Service Guide
Input Voltage 200 230 240 460 575
Input Amperes At Rated Output 32 28 27 14 11
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Circuit Breaker 1, Time-Delay 2 35 30 30 15 10
Normal Operating 3 45 40 40 20 15
Min Input Conductor Size In AWG/Kcmil 10 10 10 14 14
Max Recommended Input Conductor Length In Feet (Meters)89
(27)118(36)
128(39)
185(56)
289(88)
Min Grounding Conductor Size In AWG/Kcmil 10 10 10 14 14
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
OM-1322 Page 19Return To Table Of Contents
3-17. Selecting A Location And Connecting Input Power
1 Rating Label
Supply correct input power.
2 Plug (NEMA Type 6-50P)
3 Receptacle(NEMA Type 6-50R)
Connect plug to receptacle.
4 Input And GroundingConductors
Connect directly to line disconnectdevice if hard wiring is required.
5 Line Disconnect Device
See Section 3-16.
� Special installation may berequired where gasoline orvolatile liquids are present −see NEC Article 511 or CECSection 20.
802 717-C
L1L2
230 VAC, 1
18 in (457 mm) ofspace for airflow
� Do not move or operate unitwhere it could tip.
� Always connect grounding conductor first.
= GND/PE
3
2
5
1
4
L1
L2
OM-1322 Page 20 Return To Table Of Contents
3-18. Threading Welding Wire
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide7 Gun Conduit Cable
Lay gun cable out straight.
4
7
3 5 621
Tools Needed:
6 in(150 mm)
�Hold wire tightly to keep itfrom unraveling.
WOOD
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;continue to hold wire.
Close and tighten pressure assembly, and let go of wire.
Remove gun nozzle and contact tip. Turn On.
Press gun trigger until wire comes out of gun. Reinstall
contact tip and nozzle
Feed wire to check drive roll pressure.Tighten knob enough to prevent slipping.
Cut off wire. Close and latch door.
Ref. 802 714-B / S-0627-A
Tighten
1234
�Use pressure indicatorscale to set a desireddrive roll pressure.
PressureIndicator
Scale
Tighten
1234
OM-1322 Page 21Return To Table Of Contents
801 889-B
� Turn Off and disconnectinput power.
1 Contact Adapter
Remove existing barrel fromcontact adapter.
2 Gas Hose
Disconnect gas hose from gasnipple.
3 Straight Barrel
4 Curved Barrel
5 Locking Nut
�Before tightening locking nuton the curved barrel, the barrelcan be rotated to the desiredposition.
Install either straight or curvedbarrel onto contact adapter, andtighten locking nut.
Connect gas hose to gas nipple.
Tools Needed:
1
2
5
3
4
3-19. Installing Optional Curved Or 9 in Straight Barrel On Spoolmate 3035 Spool Gun
OM-1322 Page 22 Return To Table Of Contents
802 726
1 Side Panel
2 Latch
3 Cable Holder
Press latch down to release andopen door.
4 Holster (2)
Wrap cable around cable holder,and place gun nozzle into holster.
1
2
3-20. Using Gun/Cable Holder
3
4
OM-1322 Page 23Return To Table Of Contents
SECTION 4 − OPERATION
4-1. Controls
1 Voltage Control
Set Voltage control according to theparameter chart for good starting point.Turn control clockwise to increase voltage.
2 Wire Speed Control
Set Wire Speed control according to theparameter chart. Increase or decrease wire
speed to obtain desired bead profile andtravel speed.
3 Arc Length Control
Set Arc Length control according to theparameter chart. Use Arc Length control(pulse width) to adjust puddle fluidity andwidth of bead. Shorter arc length setting willresult in a narrower, cooler weld puddle.
Longer arc length setting will result in awider, hotter weld puddle.
4 Power Switch
This switch energizes the main transformerand control circuitry.
5 Spool Gun Receptacle
6 MIG Gun Receptacle
3
12
200 034-B
VOLTAGEWIRE SPEED
MIG GUN SPOOL GUN
−2
0−1
−3
−4
−5
1
2
3
4
5
4050
30
20
10
60
70
80
90
100
RATED OUTPUT
AMPERA GEVOLTAGEDUTY CYCLEMAX OCV
NEMA CLASS I (60)
16026
60%36
V
7
6
5
4
32
1
DO NO T SWITCHWHILE WELDING
ARC LENGTH
ON OFF
(PULSE ONLPULSE ONLY ) 4
56
OM-1322 Page 24 Return To Table Of Contents
4-2. Weld Parameter Chart
Input LineVoltage*
ParameterChart Settings
Highere.g. 240Volts AC
230 Volts AC
Lowere.g. 218Volts AC
Weld Will BeHotter
Lower Settings
Use ParameterChart Inside
Door
Weld Will BeColder
Raise Settings
*Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjustvoltage and wire feed speed to optimize your settings.
3035
OM-1322 Page 25Return To Table Of Contents
200 796-A
3035
OM-1322 Page 26 Return To Table Of Contents
4-3. Parameter Adjustment Guide
Problem Probable Cause Remedy
Erratic arc, ball at end of wiretoo large at time of transfer toweld puddle.
Arc Length control set too low. Increase arc length setting slightly (see Section 4-1).
Wire shorting (stubbing) intoweld puddle.
Wire speed set too high. Decrease wire speed setting slightly (see Section 4-1).weld puddle.
Make fine adjustment to Arc Length control setting (seeSection 4-1).
Wire burns back into gun tipat start of weld.
Voltage set too high. See parameter chart on inside of door or see Section 4-2,and readjust parameters.
Wire speed set too low. See parameter chart on inside of door or see Section 4-2,and readjust parameters.
Distance from gun tip to work is too close. Increase distance between gun tip and work toapproximately 5/8 to 3/4 in (15.9 to 19 mm).
Wire burns back into gun tipwhile welding.
Gun tip overheating. Increase distance between gun tip and work.
Weld bead appearance isrough and full of porosity.
Gas coverage at weld puddle insufficient. Set gas flow to 30 cfh (14 L/min).rough and full of porosity.
Use a gun push angle of 10 to 15 degrees.
Weld puddle too hot and wirepushes through material.
Incorrect parameter settings. See parameter chart on inside of door or see Section 4-2,and readjust parameters.
Weld puddle too cold andweld bead appearance isropy.
Incorrect parameter settings. See parameter chart on inside of door or see Section 4-2,and readjust parameters.
Weld gun is not pulsing. Gun not connected to pulse weld terminal. Check and reconnect gun weld cable if necessary (seeSection 3-10).
OM-1322 Page 27Return To Table Of Contents
SECTION 5 − MAINTENANCE &TROUBLESHOOTING
5-1. Routine Maintenance
� Disconnect power before maintaining.
�Maintain more oftenduring severe conditions.
3 Months
Replace unreadable labels Repair or replacecracked weld cable
Clean and tighten weld terminals
6 Months
Blow out or vacuum inside.
OR
Remove drive roll andcarrier. Apply light coatof oil or grease to drivemotor shaft.
Ref. 802 990
5-2. Circuit Breaker CB1
1 Circuit Breaker CB1
If CB1 opens, wire feeding stops.
2 Welding Gun
Check gun liner for blockage orkinks.
3 Wire Drive Assembly
Check for jammed wire, bindingdrive gear or misaligned drive rolls.
Allow cooling period and resetbreaker. Close door.2
Ref. 802 714-B
31
5-3. Unit Overload
Thermostats TP1 in rectifier SR1 and TP2 in stabilizer Z1 protect the unit from damage due to overheating. If TP1and/or TP2 opens, wait several minutes before trying to weld.
OM-1322 Page 28 Return To Table Of Contents
5-4. Replacing Gun Contact Tip
Ref. 800 797-C
� Turn Off power.
1 Nozzle
2 Contact Tip
Cut off welding wire at contact tip.Remove nozzle.
Remove contact tip and install newcontact tip. Reinstall nozzle.
Tools Needed:
1
2
5-5. Changing Drive Roll and Wire Inlet Guide
1 Securing Screw
2 Inlet Wire Guide
Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw.
3 Anti-Wear Guide
Install guide as shown.
4 Drive Roll
Install correct drive roll for wire sizeand type.
5 Drive Roll Securing Nut
Turn nut one click to secure driveroll.
Tools Needed:
5/64 in
7/16 in
Ref. 802 990
1
3
2
4
5
OM-1322 Page 29Return To Table Of Contents
5-6. Aligning Drive Rolls and Wire Guide
� Turn Off power.
View is from top of drive rolls look-ing down with pressure assemblyopen.
1 Drive Roll Securing Nut
2 Drive Roll3 Wire Guide
4 Welding Wire
5 Drive Gear
Insert screwdriver, and turn screwin or out until drive roll groove linesup with wire guide.
Close pressure roll assembly.
Ref. ST-800 412-A
Correct Incorrect43
21
5
Tools Needed:
5-7. Removing Knob From Front Panel
� Turn Off power.
1 Front Panel
2 Knob
3 Slot
4 Control Shaft
Rotate knob to allow access to slot.Insert tip of screwdriver into slot,and while pushing on spring clip,pull knob off control shaft.
To reinstall, push knob fully ontocontrol shaft.
803 346 / 802 717-C
3
2
14
OM-1322 Page 30 Return To Table Of Contents
5-8. Cleaning Or Replacing Gun Liner
Ref. ST-800 797-C
5/16 in, 10 mm
To Reassemble Gun:
Install and tighten new liner.
Cut liner off 3/4 in (20 mm) (3/8 in[9.5 mm] for aluminum) from headtube.
Install adapter, contact tip, andnozzle.
� Disconnect gun from unit first.Tools Needed:
Lay gun cable out straightbefore installing new liner.
Head Tube
5/16 in
Remove nozzle, contact tip, andadapter.
Blow out gun casing.
Remove liner.
10 mm
OM-1322 Page 31Return To Table Of Contents
5-9. Replacing Switch And/Or Head Tube
Ref. ST-800 795-C
1 Remove handlelocking nut.
2 Remove switch housing. Note: If installing newswitch, push switch lead connectors onto terminal ofnew switch (polarity is not important). Install switchback into handle, and secure with handle locking nut.If replacing head tube, continue to end of figure.
3 Slide handle.
4 Secure headtube in vice.
5 Loosen jam nut. Removefrom vice and turn headtube out by hand.
6 Install existing shock washer ontonew head tube. Hand-tighten headtube into connector cable.
7 Place head tube in vice and tightenuntil nuts are tight.
8 Remove from vice. Repositionhandle and install switch housing.Secure with handle locking nut.
� Disconnect gun first.
3/4 in
Tools Needed:
OM-1322 Page 32 Return To Table Of Contents
5-10. Changing Drive And Push Rolls On Spoolmate 3035
801 893-A
Tools Needed:
� Turn Off power at weldingpower source first.
1 Drive Roll Cover
Remove cover.
Changing Push Roll:
To remove push roll:
2 Push Roll Screw
3 Washer
4 Push Roll
Remove screw and washer, and liftout push roll.
To install push roll:
Slide push roll onto shaft andsecure with washer and screw.
Changing Lower Drive Roll:
To remove drive roll:
5 Lower Drive Roll Screw
6 Washer
7 Lower Drive Roll
8 Drive Roll Key
9 Drive Roll Shaft
Remove screw and washer, and liftout drive roll. Note: drive roll key willcome out with drive roll.
To install drive roll:
Place drive roll key in slot in driveroll shaft.
Line slot in drive roll up with driveroll key, and slide drive roll ontoshaft.
Secure drive roll with washer andscrew.
Reinstall gun case, if applicable.
Reinstall drive roll cover.
12
34
5
6
78
9
It may be necessary to removedrive roll side of gun case tochange lower drive roll.
OM-1322 Page 33Return To Table Of Contents
5-11. Changing Liner On Spoolmate 3035
Ref. 801 891-A
Tools Needed:
� Turn Off power at weldingpower source first.
1 Nozzle
2 Contact Tip
3 Liner
Remove and replace liner.
Reinstall parts as shown.
1
2
3
5-12. Troubleshooting
Trouble Remedy
No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-17).
Replace building line fuse or reset circuit breaker if open (see Section 3-17).
Reset circuit breaker CB1 (see Section 5-2).
Secure gun trigger connections (see Section 3-9).
Have Factory Authorized Service Agent check Power switch.
Have Factory Authorized Service Agent check all board connections and main control board.
No weld output; wire feeds. Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled(see Section 3-3).
Connect work clamp to get good metal to metal contact.
Replace contact tip (see Section 5-4).
An overload condition occurred. Release gun trigger (see Section 5-3).
Have Factory Authorized Service Agent check main control board and main rectifier.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 3-17).
Check input voltage jumper links and correct position if necessary (see Section 3-15).
Have Factory Authorized Service Agent check main control board.
OM-1322 Page 34 Return To Table Of Contents
Trouble Remedy
Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1).
Change to correct size drive rolls (see Section 5-5).
Readjust drive roll pressure (see Section 3-18).
Replace inlet guide, contact tip, and/or liner if necessary (see Sections 5-4 and 5-8).
Check position of input jumper links (see Section 3-15).
Have Factory Authorized Service Agent check main control board.
No wire feed. Reset circuit breaker CB1 (see Section 5-2).
Turn Wire Speed control to higher setting (see Section 4-1).
Clear obstruction in gun contact tip or liner (see Sections 5-4 and 5-8).
Readjust drive roll pressure (see Section 3-18).
Change to correct size drive rolls (see Section 5-5).
Rethread welding wire (see Section 3-18).
Check gun trigger and leads. Repair or replace gun if necessary.
Have Factory Authorized Service Agent check main control board.
5-13. Spool Gun Troubleshooting
Trouble Remedy
Gun tube assembly loose. Tighten nut at base of gun tube assembly.
No weld output; gun/feeder does notwork.
Place Power switch on welding power source in the On position (see welding power source Owner’sManual).
Erratic weld output. Tighten and clean all connections.
Pressing gun/feeder trigger does not en-ergize welding power source; weldingwire is not energized; shielding gas doesnot flow.
Secure plug from gun/feeder trigger cord into 4-socket receptacle on welding power source(see Section 3-10).
Wire feeds, shielding gas flows, butwelding wire is not energized.
Secure control cable leads in welding power source (see Section 3-10).welding wire is not energized.
See Troubleshooting section in welding power source Owner’s Manual.
Wire feeds erratically. Check and correct drive roll pressure (see Section 3-14).
Clean or replace drive roll; clean or replace liner (see Sections 5-10 and 5-11).
OM-1322 Page 35Return To Table Of Contents
SECTION 6 − ELECTRICAL DIAGRAM
203 535-B
Figure 6-1. Welding Power Source Circuit Diagram
OM-1322 Page 36 Return To Table Of Contents
186 451
Figure 6-2. Spool Gun Circuit Diagram
OM-1322 Page 37Return To Table Of Contents
SECTION 7 − MIG WELDING (GMAW) GUIDELINES
7-1. Typical MIG Process Connections
� Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.
light mig 5/967 / Ref. 802 714-B / Ref. 802 064-B
Wire Feeder/Power Source
Workpiece
Gun
Regulator/Flowmeter
GasHose
ShieldingGas
Supply
Work Clamp
OM-1322 Page 38 Return To Table Of Contents
7-2. Typical MIG Process Control Settings
These settings are guidelines only. Material and wire type, joint design, fitup,position, shielding gas, etc. affect settings. Test welds to be sure they comply tospecifications.
Welding wire is energized when gun trigger is pressed. Before lowering helmet andpressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,and tip of wire is positioned correctly on seam.
NOTE
1 Hold Gun and Control GunTrigger
2 Workpiece
3 Work Clamp
4 Electrode Extension (Stickout)1/4 to 1/2 in (6 To 13 mm)
5 Cradle Gun and Rest Hand onWorkpiece
23
5
4
90° 90°
0°-15°
45°
45°
GROOVE WELDS
FILLET WELDS
End View Of Work Angle Side View Of Gun Angle
End View Of Work Angle Side View Of Gun Angle
1
0°-15°
S-0421-A
OM-1322 Page 40 Return To Table Of Contents
7-4. Conditions That Affect Weld Bead Shape
Weld bead shape depends on gun angle, direction of travel, electrode extension(stickout), travel speed, thickness of base metal, wire feed speed (weld current),and voltage.
NOTE
Short Normal Long
Short Normal Long
10°
10°
GUN ANGLES AND WELD BEAD PROFILES
ELECTRODE EXTENSIONS (STICKOUT)
FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)
Push
Perpendicular Drag
GUN TRAVEL SPEED
Slow Normal Fast
S-0634
OM-1322 Page 41Return To Table Of Contents
7-5. Gun Movement During Welding
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide groove weld joints or bridging across gaps, a weave bead ormultiple stringer beads works better.
NOTE
1 Stringer Bead − SteadyMovement Along Seam
2 Weave Bead − Side To SideMovement Along Seam
3 Weave Patterns
Use weave patterns to cover a widearea in one pass of the electrode.
S-0054-A
3
1 2
7-6. Poor Weld Bead Characteristics
1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration
5
42 3
1
S-0053-A
7-7. Good Weld Bead Characteristics
1 Fine Spatter
2 Uniform Bead
3 Moderate Crater DuringWelding
Weld a new bead or layer for each1/8 in (3.2 mm) thickness in metalsbeing welded.
4 No Overlap
5 Good Penetration into BaseMetal
S-0052-B
2 3
1
4
5
OM-1322 Page 42 Return To Table Of Contents
7-8. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead.
S-0636
Possible Causes Corrective Actions
Wire feed speed too high. Select lower wire feed speed.
Voltage too high. Select lower voltage range.
Electrode extension (stickout) too long. Use shorter electrode extension (stickout).
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
7-9. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pocketsin weld metal.
S-0635
Possible Causes Corrective Actions
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
7-10. Troubleshooting − Excessive Penetration
Good Penetration
Excessive Penetration − weld metal melting through base metaland hanging underneath weld.
Excessive PenetrationS-0639
Possible Causes Corrective Actions
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-1322 Page 43Return To Table Of Contents
7-11. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallowfusion between weld metal andbase metal.
Lack of Penetration Good PenetrationS-0638
Possible Causes Corrective Actions
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove whilemaintaining proper welding wire extension and arc characteristics.
Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Incomplete Fusion − failure of weld metal to fuse completely withbase metal or a preceeding weld bead.
S-0637
Possible Causes Corrective Actions
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface beforewelding.
Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
7-13. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metalresulting in holes where no metal remains.
S-0640
Possible Causes Corrective Actions
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
OM-1322 Page 44 Return To Table Of Contents
7-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base metal.
S-0641
Possible Causes Corrective Actions
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand. Support hand on solid surface or use two hands.
7-15. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forcesbase metal to move.
Base metal movesin the direction of
the weld bead.S-0642
Possible Causes Corrective Actions
Excessive heat input. Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-1322 Page 45Return To Table Of Contents
7-16. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowing table.
Application
GasSpray Arc Steel Short Circuiting Steel
Short CircuitingStainless Steel
Aluminum
Argon X
Argon + 25% CO 2 X
80% or greater Argon +balance CO 2 or Oxygen
X X1
100% CO2 X
Tri-Mix 2 X1 Limited short circuiting use
2 90% HE + 7-1/2% AR + 2-1/2% CO2
7-17. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem Probable Cause Remedy
Wire feed motor operates, butwire does not feed.
Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.wire does not feed.
Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to matchwire size and type if necessary.
Wire spool brake pressure too high. Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip ifdamaged. Check size of contact tip and cable liner,replace if necessary.
Wire curling up in front of thewire feed rolls (bird nesting).
Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.wire feed rolls (bird nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner lengthand diameter, replace if necessary.
Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gunend into housing just enough so it does not touch wirefeed rolls.
Dirty or damaged (kinked) liner. Replace liner.
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.
Gas nozzle plugged. Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.
Restriction in gas line. Check gas hose between flowmeter and wire feeder, andgas hose in gun and cable assembly.
Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gassolenoid valve.
Incorrect primary voltage connected to welding powersource.
Check primary voltage and relink welding power sourcefor correct voltage.
OM-1322 Page 46 Return To Table Of Contents
Problem RemedyProbable Cause
Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worndrive rolls if necessary.
Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed onwelding power source.
Readjust welding parameters.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.
OM-1322 Page 47Return To Table Of Contents
Notes
OM-1322 Page 48 Return To Table Of Contents
SECTION 8 − PARTS LIST
� Hardware is common andnot available unless listed.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.♦OPTIONALTo maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1322 Page 50 Return To Table Of Contents
802 719
12
34
56
7
89
10
11
12
13
1516
1714
18
1920
2122
23
24
26
27
28
29
� Hardware is common andnot available unless listed.
22
25 −
Fig
8-6
Figure 8-2. Baffle, Center w/Components
OM-1322 Page 51Return To Table Of Contents
DescriptionPartNo.
Dia.Mkgs.
ItemNo.
Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 1)
+When ordering a component originally displaying a precautionary label, the label should also be ordered.To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1322 Page 52 Return To Table Of Contents
802 728-A
� Hardware is common andnot available unless listed.
+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 SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.
Figure 8-5. M-15 Gun♦OPTIONALTo maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1322 Page 55Return To Table Of Contents
DescriptionPartNo.
Dia.Mkgs.
ItemNo.
Figure 8-6. Wire Drive And Gears (Fig 8-2 Item 25)
� Hardware is common andnot available unless listed.
Figure 8-6. Wire Drive And Gears
See Section 8-9Drive Roll & Wire Guide Kits.
1
2
3
45
6
11
12
13
1415
16
17
18
19
2021
22
2324
25
26
17
8
9
10
7
*Recommended Spare Parts.To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1322 Page 56 Return To Table Of Contents
� Hardware is common andnot available unless listed.
♦OPTIONALTo maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.
♦OPTIONALTo maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1322 Page 59Return To Table Of Contents
8-9. Drive Roll And Wire Guide Kits
Note Base selection of drive rolls upon the following recommended usages:
1 V-Grooved rolls for hard wire.
2 U-Grooved rolls for soft and soft shelled cored wires.
3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4 V-Knurled rolls for hard shelled cored wires.
5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combinationwith U-Grooved).
Ref. S-0026-B/7-91
Wire Diameter
Fraction Decimal Metric
.023/.025 in.
.030 in.
.035 in.
.045 in.
.023/.025 in.
.030 in.
.035 in.
.045 in.
0.6 mm
0.8 mm
0.9 mm
1.2 mm
Kit No.
087 131
079 594
079 595
079 596
Drive Roll
Part No. Type
087 130
053 695
053 700
053 697
V-Grooved
V-Grooved
V-Grooved
V-Grooved
Inlet
056 192
056 192
056 192
056 193
Wire Guide
1/16 in. .062 1.6 mm 079 598 053 699 V-Grooved 056 195
.052 in. .052 1.3 mm 079 597 053 698 V-Grooved 056 193
.030/.035 in .030/.035 in 0.8/0.9 mm 204 579 203 526 V-Grooved 056 192
Notes
Notes
Notes
Warranty Questions?
Call1-800-4-A-MILLERfor your localMiller distributor.
miller_warr 8/03
Your distributor also givesyou ...
ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.
SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.
Effective January 1, 2003(Equipment with a serial number preface of “LC” or newer)This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrantsto its original retail purchaser that new Miller equipment soldafter the effective date of this limited warranty is free of defectsin material and workmanship at the time it is shipped by Miller.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair orreplace any warranted parts or components that fail due tosuch defects in material or workmanship. Miller must benotified in writing within thirty (30) days of such defect orfailure, at which time Miller will provide instructions on thewarranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warrantytime periods. All warranty time periods start on the date thatthe equipment was delivered to the original retail purchaser, orone year after the equipment is sent to a North Americandistributor or eighteen months after the equipment is sent to anInternational distributor.
1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources* Semi-Automatic and Automatic Wire Feeders* Inverter Power Supplies
(NOTE: Engines are warranted separately bythe engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of SpoolmateSpoolguns)
* Process Controllers
* Positioners and Controllers* Automatic Motion Devices* RFCS Foot Controls
* Induction Heating Power Sources* Water Coolant Systems* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units* Grids* Maxstar 85, 140* Spot Welders
* Load Banks* Racks* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAFModels)
* Field Options(NOTE: Field options are covered under TrueBlue for the remaining warranty period of theproduct they are installed in, or for a minimum ofone year — whichever is greater.)
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets* APT & SAF Model Plasma Cutting Torches* Remote Controls* Accessory Kits* Replacement Parts (No labor)* Spoolmate Spoolguns* Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,cutting nozzles, contactors, brushes, slip rings,relays or parts that fail due to normal wear.(Exception: brushes, slip rings, and relays arecovered on Bob cat, Trailblazer, and Legend models.)
2. Items furnished by Miller, but manufactured by others,such as engines or trade accessories. These items arecovered by the manufacturer’s warranty, if any.
3. Equipment that has been modified by any party otherthan Miller, or equipment that has been improperlyinstalled, improperly operated or misused based uponindustry standards, or equipment which has not hadreasonable and necessary maintenance, or equipmentwhich has been used for operation outside of thespecifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASEAND USE BY COMMERCIAL/INDUSTRIAL USERS ANDPERSONS TRAINED AND EXPERIENCED IN THE USEAND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, theexclusive remedies shall be, at Miller’s option: (1) repair; or (2)replacement; or, where authorized in writing by Miller inappropriate cases, (3) the reasonable cost of repair orreplacement at an authorized Miller service station; or (4)payment of or credit for the purchase price (less reasonabledepreciation based upon actual use) upon return of the goodsat customer’s risk and expense. Miller’s option of repair orreplacement will be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. at a Miller authorized service facility as determined byMiller. Therefore no compensation or reimbursement fortransportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIESPROVIDED HEREIN ARE THE SOLE AND EXCLUSIVEREMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FORDIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING LOSS OFPROFIT), WHETHER BASED ON CONTRACT, TORT ORANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREINAND ANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THISPROVISION, MIGHT ARISE BY IMPLICATION,OPERATION OF LAW, CUSTOM OF TRADE OR COURSEOF DEALING, INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR PARTICULARPURPOSE, WITH RESPECT TO ANY AND ALLEQUIPMENT FURNISHED BY MILLER IS EXCLUDED ANDDISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how longan implied warranty lasts, or the exclusion of incidental,indirect, special or consequential damages, so the abovelimitation or exclusion may not apply to you. This warrantyprovides specific legal rights, and other rights may beavailable, but may vary from state to state.
In Canada, legislation in some provinces provides for certainadditional warranties or remedies other than as stated herein,and to the extent that they may not be waived, the limitationsand exclusions set out above may not apply. This LimitedWarranty provides specific legal rights, and other rights maybe available, but may vary from province to province.
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03
Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA