Page 2 - To locate your nearest; Thank you; From Miller to You
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 specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-1327 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoin...
Page 6 - WELDING can cause fire or explosion.
OM-1327 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RAYS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protec...
Page 7 - ARC WELDING can cause interference.
OM-1327 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly size...
Page 9 - Symboles utilisés; Dangers relatifs au soudage à l’arc; UNE DÉCHARGE ÉLECTRIQUE peut
OM-1327 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure compor...
Page 11 - LE RAYONNEMENT HAUTE; Proposition californienne 65 Avertissements
OM-1327 Page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. ...
Page 12 - Principales normes de sécurité; Information EMF
OM-1327 Page 8 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Co...
Page 13 - A or V; WELDING AMPERES
OM-1327 Page 9 SECTION 3 − INSTALLATION 3-1. Specifications Rated Output Max. Open Circuit 60 Hz Amps Input at Rated Output Rated Output Circuit Voltage 60 Hz 200 V 230 V 460 V 575V KVA KW 300 A at 32 VDC, 60% Duty 350 A at 32 VDC, 40% Duty 90 Single-Phase 69 (1.7*) 61 (1.5*) 30 (0.75*) 24 (0.5*) 13...
Page 14 - -4. Connecting To Weld Output Terminals
OM-1327 Page 10 3-3. Volt-Ampere Curve 217 443-A 1 Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. MAXVOLTS MINVOLTS 0 50 100 150 200 250...
Page 19 - Changing Polarity; Electrode Positive
OM-1327 Page 15 3-10. Setting Gun Polarity For Wire Type 1 Polarity Changeover Information Always read and follow manufacture’s recommended polarity. 1 3/4, 11/16 in Ref. 803 541-A Changing Polarity D Wire Drive Assembly Lead Work Clamp Lead + Positive Terminal Shown as shipped − Electrode Positive ...
Page 20 - -12. Installing Wire Spool and Adjusting Hub Tension
OM-1327 Page 16 3-11. Installing Gas Supply 803 542-A Tools Needed: 1-1/8, 5/8 in 1 2 3 4 5 7 Rear Panel 6 Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve.1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open ...
Page 21 - matches the voltage specified on the rating label.
OM-1327 Page 17 3-13. Electrical Service Guide 60 Hz Single Phase 60 Hz Three Phase Input Voltage 200 230 460 575 200 230 460 575 Input Amperes At Rated Output 69 61 30 24 34 30 15 12 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 80 70 35 25 40 35 15 10 Normal Oper...
Page 23 - -15. Selecting A Location And Connecting 3-Phase Input Power
OM-1327 Page 19 3-15. Selecting A Location And Connecting 3-Phase Input Power Ref. 803 543-C / 803 766-A Y Installation must meet all National and Local Codes - have only qualified persons make this installation. Y Disconnect and lockout/tagout input power before connecting input conductors from uni...
Page 24 - -16. Selection A Location And Connecting 1-Phase Input Power
OM-1327 Page 20 3-16. Selection A Location And Connecting 1-Phase Input Power Ref. 803 543-C / 803 766-A Tools Needed: 3 2 7 6 4 Y Installation must meet all National and Local Codes - have only qualified persons make this installation. Y Disconnect and lockout/tagout input power before connecting i...
Page 25 - -17. Threading Welding Wire For Roughneck Gun
OM-1327 Page 21 3-17. Threading Welding Wire For Roughneck Gun 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide 6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 6 in (150 mm) . Hold wire tightly to keep ...
Page 27 - -19. Threading Welding Wire Through XR Guns
OM-1327 Page 23 3-19. Threading Welding Wire Through XR Guns Ref. 802 193-A / 801 556 / Ref. 151 666-C Tools Needed: Y Welding wire is electrically live when gun trigger is used to jog wire. . Refer to Section 3-18 for instruc- tions on feeding wire through welding power source. 1 Pressure Roll Asse...
Page 28 - the unit is energized.; NOTE; material type and thickness.
OM-1327 Page 24 SECTION 4 − OPERATION 4-1. Controls 1 Pulse Indicator Light . Pulse only lights if unit has the pulse MIG module and is programmed for pulse MIG. 2 MIG Indicator Lights Pulse (1) and MIG (2) illuminate to Indicate weld mode of unit.3 Process Light PROCESS illuminates when unit is in ...
Page 29 - value will appear in the corresponding display.; become the current active gun.
OM-1327 Page 25 4-3. Jog Mode If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld power. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow because gas valve is locate...
Page 30 - -9. Weld Parameters For MIG And Pulse Mode; MIG CHART; WELDCHARTS; PULSECHARTPULSECHART
OM-1327 Page 26 4-9. Weld Parameters For MIG And Pulse Mode Material Steel Steel Aluminum Stainless Steel Gas 100% Co 2 75% Argon 25% Co 2 90% Helium 7.5% Argon 2.5% Co 2 100% Argon Wire 1/2” 3/8” 1/4” 3/16” 1/8” 14ga 16ga 18ga 20ga 22ga 3/64 5356 24.0/535 23.5/500 22.5 /465 21.0 /375 19.0 /340 .035...
Page 31 - Notes
Page 32 - Suggested; Recommended Crater Parameters
OM-1327 Page 28 4-10. Recommended Crater Fill Parameters 1 / 2 " ( 1 2 . 7 m m ) What P r oc e s s a re You Using? What Material are You Welding? Suggested Wire Types Suggested Shielding Gases Wire Sizes (Diameter) Recommended Crater Parameters PULSE M I G
Page 34 - SETUP
OM-1327 Page 30 SECTION 5 − PROGRAMMING 5-1. MIG Welding Mode When the MIG light (2) is illuminated, the unit is in MIG Welding mode. SETUP To enter MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select the gun being used. Select MIG for stan...
Page 35 - OPERATION
OM-1327 Page 31 5-2. Pulse MIG Welding Mode When the PULSE MIG (1, 2) is illuminated, the unit is in Pulse MIG Welding mode. SETUP To enter Pulse MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select the gun being used. Select MIG for standar...
Page 37 - CRTR
OM-1327 Page 33 5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill Arc times and number of arc starts are saved in unit memory. To view this information, press both SETUP (1) and ARC CONTROL (2) buttons at the same time.Left display will initially show arc hours.Rotate left...
Page 39 - ALST
OM-1327 Page 35 5-6. Setting Hot Start (Aluminum Pulse Only) Parameters To access the Setup Feature Menu, press both SETUP (1) and ARC CONTROL (2) buttons at the same time. Left display will initially show arc hours. Rotate left knob (3) until ALST appears in the left display. Rotate right knob (4) ...
Page 41 - Months; before trying to weld.
OM-1327 Page 37 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals Check gun cable. 6 Mon...
Page 61 - Table 8-1. Drive Roll And Wire Guide Kits; Note
OM-1327 Page 57 Description Part No. Dia. Mkgs. 213137 Item No. Figure 8-6. Wire Drive Assembly (Continued) Quantity 24 089800 NUT, 250 − 20 .44HEX .22H STL PLD .58D FLANGE DEFOR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 602154 SCREW,250 − 20X .50 HEXWHD.50D STL PLD SLFFMG TAP −...
Page 66 - For consumable items 1 thru 7
OM-1327 Page 62 802 630-D For consumable items 1 thru 7 see Figure 8-7. 16 8 15 14 13 12 11 9 10 8 5 7 6 4 3 2 1 Figure 8-8. 4012 Gun
Page 71 - (Equipment with a serial number preface of “LF” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding quest...
Page 72 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2005 Miller Electric Mfg. Co. 10/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Europ...