Deltaweld 452 Mil

OM-203 860A
March 2002
Processes
Gas Metal Arc (MIG) Welding
Description
Arc Welding Power Source
Auto Deltaweld
452
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www.MillerWelds.com
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 offers a Technical

Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
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 orindividual catalog 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.
TABLE OF CONTENTS
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . 3
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The following terms are 1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
used interchangeably SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 5
throughout this manual:
Mig = GMAW 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WARNING 2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
This product, when used 2-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
for welding or cutting,
produces fumes or 2-7. 115 VAC Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
gases which contain 2-8. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
chemicals known to the 2-11. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
State of California to 2-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
cause birth defects and,
2-13. Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
in some cases, cancer.
(California Health & 2-14. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety Code Section SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
25249.5 et seq.) 3-1. Upper Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-3. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 4 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-3. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-5. Front Panel Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-6. Weld Interface Board PC12 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-7. Diagnostic LED’s On Weld Interface Board PC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-8. Customer Interface Board PC14 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-9. Diagnostic LED’s On Customer Interface Board PC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-10. Motor Board PC13 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-11. Diagnostic LED’s On Motor Board PC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 6 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPTIONS AND ACCESSORIES
WARRANTY
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to D If earth grounding of the workpiece is required, ground it directly
call attention to and identify possible hazards. When you see with a separate cable.
the symbol, watch out, and follow the related instructions to D Do not touch electrode if you are in contact with the work, ground,
avoid the hazard. The safety information given below is only or another electrode from a different machine.
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all D Use only well-maintained equipment. Repair or replace damaged
Safety Standards. parts at once. Maintain unit according to manual.
Y Only qualified persons should install, operate, maintain, and D Wear a safety harness if working above floor level.
repair this unit. D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away. D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
ELECTRIC SHOCK can kill. contact with any metal object.
D Do not connect more than one electrode or work cable to any
Touching live electrical parts can cause fatal shocks single weld output terminal.
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input SIGNIFICANT DC VOLTAGE exists after removal of
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the input power on inverters.
wire, wire reel, drive roll housing, and all metal parts touching the D Turn Off inverter, disconnect input power, and discharge input
welding wire are electrically live. Incorrectly installed or improperly capacitors according to instructions in Maintenance Section
grounded equipment is a hazard. before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
FUMES AND GASES can be hazardous.
or covers big enough to prevent any physical contact with the work
or ground. Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
D Do not use AC output in damp areas, if movement is confined, or if health.
there is a danger of falling.
D Use AC output ONLY if required for the welding process. D Keep your head out of the fumes. Do not breathe the fumes.
D If AC output is required, use remote output control if present on D If inside, ventilate the area and/or use exhaust at the arc to remove
unit. welding fumes and gases.
D Disconnect input power or stop engine before installing or D If ventilation is poor, use an approved air-supplied respirator.
servicing this equipment. Lockout/tagout input power according to D Read the Material Safety Data Sheets (MSDSs) and the
OSHA 29 CFR 1910.147 (see Safety Standards). manufacturer’s instructions for metals, consumables, coatings,
D Properly install and ground this equipment according to its cleaners, and degreasers.
Owner’s Manual and national, state, and local codes. D Work in a confined space only if it is well ventilated, or while
D Always verify the supply ground – check and be sure that input wearing an air-supplied respirator. Always have a trained watch-
power cord ground wire is properly connected to ground terminal in person nearby. Welding fumes and gases can displace air and
disconnect box or that cord plug is connected to a properly lower the oxygen level causing injury or death. Be sure the breath-
grounded receptacle outlet. ing air is safe.
D When making input connections, attach proper grounding conduc- D Do not weld in locations near degreasing, cleaning, or spraying op-
tor first – double-check connections. erations. The heat and rays of the arc can react with vapors to form
D Frequently inspect input power cord for damage or bare wiring – highly toxic and irritating gases.
replace cord immediately if damaged – bare wiring can kill. D Do not weld on coated metals, such as galvanized, lead, or
D Turn off all equipment when not in use. cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
D Do not use worn, damaged, undersized, or poorly spliced cables. air-supplied respirator. The coatings and any metals containing
D Do not drape cables over your body. these elements can give off toxic fumes if welded.
OM-203 860 Page 1

ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks going near arc welding, gouging, or spot
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder – explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.
OM-203 860 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

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
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.

H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories. D High-frequency (H.F.) can interfere with radio
D Use equipment of adequate capacity to lift and navigation, safety services, computers, and
support unit. communications equipment.
D If using lift forks to move unit, be sure forks are D Have only qualified persons familiar with
long enough to extend beyond opposite side of electronic equipment perform this installation.
unit. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
OVERUSE can cause OVERHEATING D If notified by the FCC about interference, stop using the
equipment at once.
D Allow cooling period; follow rated duty cycle. D Have the installation regularly checked and maintained.
D Reduce current or reduce duty cycle before D Keep high-frequency source doors and panels tightly shut, keep
starting to weld again. spark gaps at correct setting, and use grounding and shielding to
D Do not block or filter airflow to unit. minimize the possibility of interference.
STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling
boards or parts. ARC WELDING can cause interference.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards. D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
MOVING PARTS can cause injury. such as robots.
D Be sure all equipment in the welding area is
D Keep away from moving parts. electromagnetically compatible.
D Keep away from pinch points such as drive D To reduce possible interference, keep weld cables as short as
rolls. possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury. D Be sure this welding machine is installed and grounded
according to this manual.
D Do not press gun trigger until instructed to do D If interference still occurs, the user must take extra measures
so. such as moving the welding machine, using shielded cables,
D Do not point gun toward any part of the body, using line filters, or shielding the work area.
other people, or any metal when threading
welding wire.
1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 from Compressed Gas Association, 1235 Jefferson Davis Highway,
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten- Suite 501, Arlington, VA 22202.
dent of Documents, U.S. Government Printing Office, Washington, D.C. Code for Safety in Welding and Cutting, CSA Standard W117.2, from
20402. Canadian Standards Association, Standards Sales, 178 Rexdale
Recommended Safe Practices for the Preparation for Welding and Cut- Boulevard, Rexdale, Ontario, Canada M9W 1R3.
ting of Containers That Have Held Hazardous Substances, American Safe Practices For Occupation And Educational Eye And Face
Welding Society Standard AWS F4.1, from American Welding Society, Protection, ANSI Standard Z87.1, from American National Standards
550 N.W. LeJeune Rd, Miami, FL 33126 Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire Protec- Cutting And Welding Processes, NFPA Standard 51B, from National
tion Association, Batterymarch Park, Quincy, MA 02269. Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-203 860 Page 3

1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
OM-203 860 Page 4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des

Y Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
. Signifie NOTA ; n’est pas relatif à la sécurité. éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc

Y Les symboles présentés ci-après sont utilisés tout au long du D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
présent manuel pour attirer votre attention et identifier les risques champ les pièces endommagées. Entretenir l’appareil conformément
de danger. Lorsque vous voyez un symbole, soyez vigilant et à ce manuel.
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer D Porter un harnais de sécurité quand on travaille en hauteur.
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de D Maintenir solidement en place tous les panneaux et capots.
sécurité. D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
Y L’installation, l’utilisation, l’entretien et les réparations ne doi- avec la pièce à souder ou la table de travail, le plus près possible de la
vent être confiés qu’à des personnes qualifiées. soudure.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus par- D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
ticulièrement les enfants. avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.

Il y a DU COURANT CONTINU IMPORTANT dans les
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves. convertisseurs après la suppression de l’alimenta-
L’électrode et le circuit de soudage sont sous tension tion électrique.
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous D Arrêter les convertisseurs, débrancher le courant électrique, et dé-
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces charger les condensateurs d’alimentation selon les instructions
métalliques en contact avec le fil de soudage sont sous tension. Des indiquées dans la partie entretien avant de toucher les pièces.
matériels mal installés ou mal mis à la terre présentent un danger.
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres LES FUMÉES ET LES GAZ peuvent
moyens isolants suffisamment grands pour empêcher le contact phy-
sique éventuel avec la pièce ou la terre. être dangereux.
D Ne pas se servir de source électrique àcourant électrique dans les zones Le soudage génère des fumées et des gaz. Leur
humides, dans les endroits confinés ou là où on risque de tomber. inhalation peut être dangereux pour votre santé.
D Se servir d’une source électrique àcourant électrique UNIQUEMENT si le D Eloigner votre tête des fumées. Ne pas respirer
procédé de soudage le demande. les fumées.
D Si l’utilisation d’une source électrique àcourant électrique s’avère néces- D A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
saire, se servir de la fonction de télécommande si l’appareil en est équipé. de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal- D Si la ventilation est insuffisante, utiliser un respirateur à alimenta-
lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller tion d’air homologué.
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité). D Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consomma-
D Installer et mettre à la terre correctement cet appareil conformément à bles, les revêtements, les nettoyants et les dégraisseurs.
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux. D Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assu- surveillant dûment formé de se tenir à proximité. Des fumées et des
rer que le fil de terre du cordon d’alimentation est bien raccordé à la gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxy-
borne de terre du sectionneur ou que la fiche du cordon est raccordée gène provoquant des blessures ou des accidents mortels. S’assu-
à une prise correctement mise à la terre. rer que l’air de respiration ne présente aucun danger.
D En effectuant les raccordements d’entrée fixer d’abord le conducteur D Ne pas souder dans des endroits situés à proximité d’opérations de
de mise à la terre approprié et contre-vérifier les connexions. dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas rayons de l’arc peuvent réagir en présence de vapeurs et former des
endommagé ou dénudé – remplacer le cordon immédiatement s’il est gaz hautement toxiques et irritants.
endommagé – un câble dénudé peut provoquer une électrocution. D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
D Mettre l’appareil hors tension quand on ne l’utilise pas. galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi- ment n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
sante ou mal épissés. ventilé, et si nécessaire, en portant un respirateur à alimentation
D Ne pas enrouler les câbles autour du corps. d’air. Les revêtements et tous les métaux renfermant ces éléments
D Si la pièce soudée doit être mise à la terre, le faire directement avec un peuvent dégager des fumées toxiques en cas de soudage.
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
OM-203 860 Page 5

LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris-
voquer des brûlures dans les yeux et quent de provoquer des blessures ou
sur la peau. même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas de
(ultraviolets et infrarouges) susceptibles de provoquer non utilisation.
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
pendant le soudage. rateur d’adduction d’air homologué.
D Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des protections approuvés pour les oreilles si le niveau sondre est DES PIÈCES CHAUDES peuvent pro-
trop élevé. voquer des brûlures graves.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas re- D Ne pas toucher des parties chaudes à mains nues
garder l’arc. D Prévoir une période de refroidissement avant
D Porter des vêtements de protection constitué dans une matière dura- d’utiliser le pistolet ou la torche.
ble, résistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un

incendie ou une explosion. LES CHAMPS MAGNÉTIQUES peuvent
Le soudage effectué sur des conteneurs fermés tels
affecter les stimulateurs cardiaques.
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être D Porteurs de stimulateur cardiaque, restez à distance.
projetées de l’arc de soudure. La projection d’étincel- D Les porteurs d’un stimulateur cardiaque doivent
les, des pièces chaudes et des équipements chauds peut provoquer des d’abord consulter leur médecin avant de s’approcher
incendies et des brûlures. Le contact accidentel de l’électrode avec des des opérations de soudage à l’arc, de gougeage ou
objets métalliques peut provoquer des étincelles, une explosion, un de soudage par points.
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud. LE BRUIT peut affecter l’ouïe.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables. Le bruit des processus et des équipements peut affecter
D Déplacer toutes les substances inflammables à une distance de 10,7 l’ouïe.
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneuse-
ment avec des protections homologués. D Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
D Des étincelles et des matériaux chauds du soudage peuvent facile-
ment passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-
mité. Si des BOUTEILLES sont endomma-
D Le soudage effectué sur un plafond, plancher, paroi ou séparation gées, elles pourront exploser.
peut déclencher un incendie de l’autre côté.
Des bouteilles de gaz protecteur contiennent du gaz
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des sous haute pression. Si une bouteille est endomma-
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa- gée, elle peut exploser. Du fait que les bouteilles de gaz
rés correctement conformément à AWS F4.1 (voir les normes de font normalement partie du procédé de soudage, les
sécurité). manipuler avec précaution.
D Brancher le câble sur la pièce le plus près possible de la zone de sou-
dage pour éviter le transport du courant sur une longue distance par D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chemins inconnus éventuels en provoquant des risques d’élec- des chocs mécaniques, du laitier, des flammes ouvertes, des étin-
trocution et d’incendie. celles et des arcs.
D Ne pas utiliser le poste de soudage pour dégeler des conduites ge- D Placer les bouteilles debout en les fixant dans un support stationnai-
lées. re ou dans un porte-bouteilles pour les empêcher de tomber ou de
D En cas de non utilisation, enlever la baguette d’électrode du porte- se renverser.
électrode ou couper le fil à la pointe de contact. D Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
D Porter des vêtements de protection dépourvus d’huile tels que des cuits électriques.
gants en cuir, une chemise en matériau lourd, des pantalons sans re- D Ne jamais placer une torche de soudage sur une bouteille à gaz.
vers, des chaussures hautes et un couvre chef. D Une électrode de soudage ne doit jamais entrer en contact avec une
D Avant de souder, retirer toute substance combustible de vos poches bouteille.
telles qu’un allumeur au butane ou des allumettes. D Ne jamais souder une bouteille pressurisée – risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
DES PARTICULES VOLANTES les maintenir ainsi que les éléments associés en bon état.
peuvent blesser les yeux. D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
D Le soudage, l’écaillement, le passage de la pièce D Maintenir le chapeau de protection sur la soupape, sauf en cas d’uti-
à la brosse en fil de fer, et le meulage génèrent lisation ou de branchement de la bouteille.
des étincelles et des particules métalliques vo- D Lire et suivre les instructions concernant les bouteilles de gaz com-
lantes. Pendant la période de refroidissement des soudures, elles ris- primé, les équipements associés et les publications P-1 CGA énu-
quent de projeter du laitier. mérées dans les normes de sécurité.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-203 860 Page 6

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU DES ORGANES MOBILES peuvent

D’EXPLOSION. provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le
mité de surfaces infllammables. ventilateur.
D Ne pas installer l’appareil à proximité de produits inflammables D Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
D Ne pas surcharger l’installation électrique – s”assurer que l’alimen- protection.
tation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
LA CHUTE DE L’APPAREIL peut des interférences.
blesser.
D Le rayonnement haute frequence peut provoquer
D Utiliser l’anneau de levage uniquement pour sou- des interférences avec les équipements de ra-
lever l’appareil, NON PAS les chariot, les bouteil- dio–navigation et de communication, les services
les de gaz ou tout autre accessoire. de sécurité et les ordinateurs.
D Utiliser un engin d’une capacité appropriée pour D Demander seulement à des personnes qualifiées familiarisées
soulever l’appareil. avec des équipements électroniques de faire fonctionner l’installa-
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer tion.
que les fourches sont suffisamment longues pour dépasser du côté D L’utilisateur est tenu de faire corriger rapidement par un électricien
opposé de l’appareil. qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appa-
reil.
L’EMPLOI EXCESSIF peut D Effectuer régulièrement le contrôle et l’entretien de l’installation.
SURCHAUFFER L’ÉQUIPEMENT. D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
D Prévoir une période de refroidissement, respec- correcte et utiliser une terre et et un blindage pour réduire les interfé-
ter le cycle opératoire nominal. rences éventuelles.
D Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
D Ne pas obstruer les passages d’air du poste. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
LES CHARGES ÉLECTROSTATI- D L’énergie électromagnétique risque de provoquer
QUES peuvent endommager les des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
circuits imprimés. commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit com-
D Établir la connexion avec la barrette de terre patible électromagnétiquement.
avant de manipuler des cartes ou des pièces.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
D Utiliser des pochettes et des boîtes antistatiques soudage aussi courts que possible, les grouper, et les poser aussi
pour stocker, déplacer ou expédier des cartes de bas que possible (ex. par terre).
circuits imprimes.
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
DES ORGANES MOBILES peuvent D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
provoquer des blessures. D En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires tel-
D Ne pas s’approcher des organes mobiles. les que le déplacement du poste, l’utilisation de câbles blindés, l’uti-
D Ne pas s’approcher des points de coincement lisation de filtres de ligne ou la pose de protecteurs dans la zone de
tels que des rouleaux de commande. travail.
LES CHAMPS MAGNÉTIQUES peuvent

LES FILS DE SOUDAGE peuvent affecter les stimulateurs cardiaques.
provoquer des blessures.
D Porteurs de stimulateur cardiaque, restez à dis-
D Ne pas appuyer sur la gachette avant d’en avoir tance.
reçu l’instruction. D Les porteurs d’un stimulateur cardiaque doivent
D Ne pas diriger le pistolet vers soi, d’autres person- d’abord consulter leur médecin avant de s’appro-
nes ou toute pièce mécanique en engageant le fil cher des opérations de soudage à l’arc, de gou-
de soudage. geage ou de soudage par points.
OM-203 860 Page 7

1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés connexes, norme
20402. CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS Safe Practices For Occupation And Educational Eye And Face Protec-
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL tion, norme ANSI Z87.1, de l’American National Standards Institute,
33126 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, de la National Fire Protec- Cutting and Welding Processes, norme NFPA 51B, de la National Fire
tion Association, Batterymarch Park, Quincy, MA 02269. Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme, Afin de réduire les champs électromagnétiques dans l’environnement
des champs magnétiques basse fréquence de travail, respecter les consignes suivantes :
1 Garder les câbles ensembles en les torsadant ou en les
Le courant de soudage, pendant son passage dans les câbles de sou- attachant avec du ruban adhésif.
dage, causera des champs électromagnétiques. Il y a eu et il y a encore 2 Mettre tous les câbles du côté opposé de l’opérateur.
un certain souci à propos de tels champs. Cependant, après avoir ex- 3 Ne pas courber pas et ne pas entourer pas les câbles autour de
aminé plus de 500 études qui ont été faites pendant une période de votre corps.
recherche de 17 ans, un comité spécial ruban bleu du National Re- 4 Garder le poste de soudage et les câbles le plus loin possible de
search Council a conclu: “L’accumulation de preuves, suivant le vous.
jugement du comité, n’a pas démontré que l’exposition aux champs
5 Relier la pince de masse le plus près possible de la zone de
magnétiques et champs électriques à haute fréquence représente un
soudure.
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les con- Consignes relatives aux stimulateurs cardiaques :
clusions finales de la recherche soient établies, il vous serait Les personnes qui portent un stimulateur cardiaque doivent avant tout
souhaitable de réduire votre exposition aux champs électromagnéti- consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
ques pendant le soudage ou le coupage. alors recommandé de respecter les consignes ci–dessus.
OM-203 860 Page 8

SECTION 2 – INSTALLATION
2-1. Specifications
Amperes Input at Rated Load Output, 50 or 60 Hz,

Rated Three-Phase
Welding Voltage Max OCV
Model Output Range DC DC 200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW
450 A @ 38
(36.5) Volts 72 63 39 37 33 32 25 25.1 21.1
450 Amp 10 – 38 48
DC, 100% 3.2* 2.7* 2.6* 2.2* 2.1* 1.4* 1.1* 1.09* 0.26*
Duty Cycle
*While idling
2-2. Duty Cycle And Overheating

RATED OUTPUT
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
1000 without overheating.
If unit overheats, thermostat(s)
800
opens, output stops, and cooling
WELD AMPERES
fan runs. Wait fifteen minutes for

600
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
400
warranty.
300
40 50 60 70 80 90 100
% DUTY CYCLE
100% Duty Cycle
Continuous Welding
Overheating
0 V
15
OR
Minutes Reduce Duty Cycle duty1 4/95 / Ref. 168 918
OM-203 860 Page 9

2-3. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amper-
age output capabilities of unit.
Curves of other settings fall be-
tween curves shown.
va_curve1 – 4/95 – 171 224 / 171 225 / 171 226
2-4. Selecting A Location

1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
Movement move unit.
If using lifting forks, extend forks
1 beyond opposite side of unit.
3 Rating Label
Use rating label to determine input
power needs. Label located under
front access door.
OR
4 Line Disconnect Device
2
Locate unit near correct input pow-
er supply.
Y Special installation may be
Location And Airflow required where gasoline or
4
volatile liquids are present –
see NEC Article 511 or CEC
3 Section 20.
18 in
(460 mm)
18 in
(460 mm)
802 962
OM-203 860 Page 10

2-5. Dimensions And Weights
Dimensions
C
D Height 27-1/4 in (692 mm)
E
4 Holes Width 22-1/4 in (565 mm)
Depth 35-3/4 in (908 mm)
A 35 in (889 mm)
B 1-1/4 in (32 mm)

A
C 21 in (533 mm)
D 1-3/16 in (30 mm)
E 7/16 in (11 mm) Dia
Weight
450 Amp 384 lb (174 kg)

B Ref. 153 556-A
2-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
2-7. 115 VAC Receptacle And Circuit Breakers

Y Turn Off power before con-
necting to receptacle.
1 115 V 15 A AC Receptacle
RC9
Power is shared between RC9 and
Remote 14 receptacle RC8.
3
2 Circuit Breaker CB1
3 Circuit Breaker CB2
2
CB1 protects the 115 volts ac por-
tion of RC8 and RC9 from overload.
CB2 protects the 24 volts ac portion
of RC8.
1
Press button to reset breaker.
Ref. 800 166-D
OM-203 860 Page 11

2-8. Connection Diagram
5
. The proper robot adapter cord
2 must be connected to the
3
interface unit to allow it to be
4 connected to the robot.
1 1 Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
6 3 Gas Cylinder
7 4 Gas Hose
13 5 Robot Control
8
6 Robot Input/Output Cable
7 Remote Program Select
Cable (Optional)
8 Gas And Motor Control Cable
11 12 9 Welding Power
Source/Interface Unit
10 Negative (–) Weld Cable
11 Workpiece
9
12 Voltage Sensing Lead
. Positive (+) voltage sensing
lead is contained in the motor
cable.
13 Positive (+) Weld Cable
10
802 963
2-9. Weld Output Terminals And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding

Y Turn off power before
connecting to weld out- 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
put terminals. 100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Y Do not use worn, dam-

Welding 10 – 60% 60 – 100%
aged, undersized, or poorly 10 – 100% Duty Cycle
Amperes Duty Cycle Duty Cycle
spliced cables.
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
Negative 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
Positive
High 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
Inductance Positive
Low 600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
Inductance
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for
the mm2 equivalent weld cable sizes. S-0007-E
OM-203 860 Page 12

2-10. Electrical Service Guide
60 Hertz Models 450 Amp Model
Input Voltage 200 230 460 575
Input Amperes At Rated Output 72 63 32 25
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 90 70 40 30
Normal Operating 3 110 90 45 40
Min Input Conductor Size In AWG/Kcmil 4 6 8 10
163 142 366 379
Max Recommended Input Conductor Length In Feet (Meters)
(50) (43) (112) (115)
Min Grounding Conductor Size In AWG/Kcmil 6 8 10 10
Reference: 1999 National Electrical Code (NEC)

1 Consult factory for circuit breaker applications.
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).
50 Hertz Models 450 Amp Model

Input Voltage 380 400 440
Input Amperes At Rated Output 39 37 33
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 45 45 40
Normal Operating 3 60 50 50
Min Input Conductor Size In AWG/Kcmil 8 8 8
250 277 335
Max Recommended Input Conductor Length In Feet (Meters)
(76) (84) (102)
Min Grounding Conductor Size In AWG/Kcmil 10 10 10
Reference: 1999 National Electrical Code (NEC)

1 Consult factory for circuit breaker applications.
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-203 860 Page 13

2-11. Placing Jumper Links
Y Disconnect and lockout/tag-
out input power before
installing or moving jumper
links.
Check input voltage available at
site.
1 Jumper Link Label
Check label – only one is on unit.
2 Jumper Links
Move jumper links to match input
voltage.
Close access door, or go on to
Section 2-12.
200 VOLTS 230 VOLTS 460 VOLTS
Ref. S-174 976-A
230 VOLTS 460 VOLTS 575 VOLTS
1
Ref. S-174 973-A
220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS
(FACTORY OPTION) Ref. S-174 975-A
Tools Needed:
3/8 in Do not overtighten

jumper link nuts.
3/8 in
Ref. ST-800 103-A
OM-203 860 Page 14

2-12. Connecting Input Power
Y Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
Y Have only qualified persons make
this installation.
See rating label on unit and check input
= GND/PE Earth Ground voltage available at site.
1 Line Disconnect Device
2 Input Conductors
1 3 Grounding Conductor
Select size and length using Section 2-10.
Conductors must comply with national,
state, and local electrical codes. If applica-
ble, use lugs of proper amperage capacity
9 and correct hole size.
8 4 Strain Relief
Route conductors through strain relief.
7 4
5 Machine Grounding Terminal
3 6 Line Terminals
When making connections in Y Make input power connections to
the line disconnect device, the welding power source before
connect the Green Or
Green/Yellow conductor first. making connections into a deener-
gized line disconnect device.
Connect green or green/yellow grounding
Install conductors into conductor to machine grounding terminal
a deenergized line first. Then connect input conductors to line
disconnect device. terminals.
Close access door.
IMPORTANT 7 Disconnect Device (Supply)
3 Grounding Terminal
6 Input Contactor
Make connections 8 Disconnect Device Line Terminals
to machine first and Y In the deenergized line disconnect
supply last. L1 (U) device, connect green or green/yel-
2 L2 (V) low grounding conductor to sup-
ply grounding terminal first, never
L3 (W) to a line terminal. Be sure ground-
3 ing conductor goes to an earth
ground.
Connect input conductors to line termi-
nals.
10 3 9 Overcurrent Protection
5
GND/ PE Connect Green Or Green/Yellow Select type and size using Section 2-10
GND/PE Conductor First. (fused disconnect switch shown).
Close door on line disconnect device.
10 Reed Switch (Ground Current
Sensor) (Optional)
If unit is equipped with optional ground cur-
rent sensor, route grounding conductor
through reed switch two times and con-
Tools Needed: nect to ground terminal.
3/8 in Close access door.
3/8 in
ST-800 103-B / Ref. ST-801 116
OM-203 860 Page 15

2-13. Front Panel Connections
1 2
A
B M
C L
P NT
D K
R S J
E H
FG
Example Receptacle
5 6
3 4
Ref. S-0003-A / Ref. 203 394
1 Receptacle cord to work. To connect matching interconnecting cord

to one of the above receptacles, align key-
2 Keyway 4 Peripheral Receptacle way, insert plug, and tighten threaded col-
3 4-Pin Receptacle (Optional External lar. Connect remaining end of cord to
Receptacle provides connection to water
Voltage Sensing Connection) matching receptacle on applicable equip-
flow switch, jog +/–, and shielding gas
ment (see Section 2-8).
To connect interconnecting cord to recep- purge circuitry.
tacle, align keyway, insert plug, and tighten 6 10-Socket Receptacle (Wire
threaded collar. 5 Robot Control Receptacle (Remote Feed/Shielding Gas Control
Program Select Connection To Robot Connection To Motor Drive
Secure ring terminal on remaining end of Control) Assembly)
OM-203 860 Page 16

2-14. Peripheral Receptacle Functions
Function Socket Socket Information
C* Circuit common.
Purge
D Contact closure to C completes 24 volts dc
solenoid circuit to purge shielding gas line.
E Contact closure to F indicates coolant flow switch is

Coolant Flow closed and recirculating coolant system is
A K Switch Input operational.
B J Signal
M F* Circuit common.
C L H
Jog + H** Contact closure to circuit common advances
D
E F welding wire at wire drive assembly.
Jog – J** Contact closure to circuit common retracts welding

Rer. 203 394 wire at wire drive assembly.
*Circuit common is same electrical reference point.

**Speed of Jog + and Jog – defaults to 200 ipm.
Note: A matching amphenol plug is supplied with a flow switch jumper.
OM-203 860 Page 17

SECTION 3 – OPERATION
3-1. Upper Front Panel Controls
8 9
1 2 3 4 5 6
1 Jog Forward Push Button 4 Gas Indicator LED LED lights when welding power source
Advances wire out of the gun. LED lights when gas solenoid is energized. contactor is energized.
7 Main Display
2 Wirefeed Indicator LED 5 Purge Push Button
Shows system state, error messages, com-
LED lights when wire feed motor is Momentarily energizes gas solenoid to mands at idle and actual feedback during
energized. purge air from gun shielding gas line, or to welding.
3 Jog Reverse Push Button adjust shielding gas regulator. 8 Motor Circuit Breaker
Retracts wire up into the gun. 6 Contactor Indicator LED 9 High Temperature Shutdown Light
Ref. 203 394
3-2. Meter Functions

Mode Meter Reading At Idle Meter Reading While Welding
V IPM V A IPM
MIG 24.5V 0I 24.5V 0A 0I
Command Volts Command WFS Actual Volts Actual Amps Actual WFS
OM-203 860 Page 18

3-3. Resetting Memory
1 Front Panel Control Buttons
2 2 Power Switch On Front Panel
1
. All three buttons must be held
Jog Reverse down for 3 seconds after unit is
Button energized.
Jog Forward Purge
Button Press and hold down all three
Button buttons while turning On unit.
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
Y Disconnect power . Maintain more often

before maintaining. during severe conditions.
3 Months
Replace Repair or Replace

damaged or replace cracked
unreadable cracked torch body.
label. cables.
Repair or
replace cracked
cables and cords.
6 Months
Clean and
tighten weld Blow out
terminals. inside.
OM-203 860 Page 19

4-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 800 453-A
4-3. Fuse F1
Y Turn Off power before open-
ing rear access door.
1 Fuse Holder Cover
2 Fuse F1 (See Parts List For
Rating)
Fuse F1 protects control transform-
er from overload. If F1 opens, weld
output and fan motor stops. Re-
place F1.
2
1
Tools Needed:
3/8 in
Turn Pull Out And Replace Fuse Turn

(Install Flat End Of Fuse Into Cover)
Ref. 800 101-C
4-4. Short Circuit Shutdown

When contact tip is shorted and sticks to workpiece, the unit output falls to a safe operating level. To resume operation,
release gun trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged.
Turn On unit to continue operation.
OM-203 860 Page 20

4-5. Front Panel Error Displays
1 7
Mem CRC E r r o r S t o p We l d C y c l e E r r
2 8
Mem R a n g e E r r N o F l o w D e t e c t e d
3 9
N o V o l t S e n s e d E r r o r G r d C u r r e n t D e t e c t
4 10
N o T a c h S e n s e d E r r o r W i r e S t i c k E r r o r
5 11
A r c S t o p E r r o r A r c F a i l T i me O u t E r r
6 12
A r c S t a r t E r r o r N o I n p u t I PM
1 Memory CRC Error Display The motor tachometer feedback is not 9 Ground Current Detect Error Display
reaching the control.
Corrupted program data has been detected Weld current has been detected in the earth
or loaded. The “X” value indicates the pro- May be caused by obstructions in the wire ground connection.
gram number. feed system or a faulty wire drive system.
May be caused by a conductor making
May be caused by incompatible information 5 Arc Stop Error Display connection to the unit chassis.
on the data card or bad memory. Trouble is occurring at arc end.
10 Wire Stick Error Display
2 Memory Range Error Display May be caused by obstructions in the wire
feed system or a faulty wire drive system or The welding wire has stuck to the workpiece
Improper welding power source range is torch is touching part at end of weld. at the end of the weld.
selected. The “X” value indicates the pro-
gram number. 6 Arc Start Error Display May be caused by poor weld conditions.
Trouble is occurring at arc start. 11 Arc Fail Time Out Error Display
May be caused by improper range settings
or improper data loaded into the interface May be caused by obstructions in the wire An arc was not established within the allotted
unit. feed system or a faulty wire drive system. time.
3 No Volt Sensed Error Display 7 Stop Weld Cycle Error Display May be caused by an inoperable wire drive,
An error has been detected and the robot absence of shield gas, or improperly operat-
The arc voltage sense circuit did not receive
hasn’t stopped the weld cycle, causing the ing welding power source.
feedback within the required time after an arc
interface unit to stop the weld cycle and wait
was established. 12 No Input IPM Display
for the robot to stop.
May be caused by an inability to establish an 8 No Flow Detected Analog IPM (inches per minute) from robot is
arc in the pulse schedule, or a lack of voltage not being received.
feedback. No coolant is detected after preflow in the
weld cycle. Check coolant system and flow May be caused by having no wire feed speed
4 No Tach Sensed Error Display switch for proper operation. programmed at the robot.
OM-203 860 Page 21

4-6. Weld Interface Board PC12 Diagnostic LED’s
1 Weld Interface Board PC12
Diagnostic LED’s are visible inside
unit, located on PC12 (see illustration
for board location).
Refer to Section 4-7 for information
on diagnostic LED’s.
LED8 LED10
LED2 LED4 LED11 Reinstall cover and left side panel
LED6 after checking diagnostic LED’s.
LED7
LED1 LED3 LED5 LED9 LED12
LED13
Front
Top View
191 842 / 802 996
OM-203 860 Page 22

4-7. Diagnostic LED’s On Weld Interface Board PC12
LED Status Diagnosis
1 On Indicates auxiliary output relay is not energized.

Off Indicates auxiliary output relay is energized.
2 On Indicates gas valve is not energized.
Off Indicates gas valve is energized.
3 On Indicates +24 volts dc is present for gas valve.
Off Indicates +24 volts dc is not present for gas valve.
4 On Indicates +15 volts dc is present on weld interface board PC12.
Off Indicates +15 volts dc is not present on weld interface board PC12.
5 On Indicates –15 volts dc is present on weld interface board PC12.
Off Indicates –15 volts dc is not present on weld interface board PC12.
6 On Indicates +15 volts dc power source supply is present on weld interface board PC12.
Off Indicates +15 volts dc power source supply is not present on weld interface board PC12.
7 On Indicates –15 volts dc power source supply is present on weld interface board PC12.
Off Indicates –15 volts dc power source supply is not present on weld interface board PC12.
8 On Indicates +5 volts dc is present on weld interface board PC12.
Off Indicates +5 volts dc is not present on weld interface board PC12.
9 On Input signal for no Jog retract.
Off Input signal for Jog retract.
10 On Input signal for no Jog advance.
Off Input signal for Jog advance.
11 On Indicates CV mode is selected.
Off Indicates CC mode is selected.
12 On Input signal for no welding power source contactor.
Off Input signal for welding power source contactor.
13 On Indicates an Emergency Stop condition is not present.

Off Indicates an Emergency Stop condition is present.
OM-203 860 Page 23

4-8. Customer Interface Board PC14 Diagnostic LED’s
1 Customer Interface Board PC14
for board location).
Reinstall front control panel after
checking diagnostic LED’s.
LED8
LED6 LED12 LED16
LED10 LED14 LED23
LED9 LED15 LED25
LED7 LED11 LED13 LED22 LED24
1 LED5
LED4 LED21
LED20
LED19
LED3 LED18
LED17
LED2
LED1
Front Control
Panel Removed
Front View
802 995
OM-203 860 Page 24

4-9. Diagnostic LED’s On Customer Interface Board PC14
On Indicates –15 volts dc RA supply is present on customer interface board PC14.

1
Off Indicates –15 volts dc RA supply is not present on customer interface board PC14.
On Indicates +15 volts dc RA supply is present on customer interface board PC14.
2
Off Indicates +15 volts dc RA supply is not present on customer interface board PC14.
On Input signal On from robot for no Emergency Stop.
3
Off Input signal Off from robot for Emergency Stop.
On Indicates +24 volts dc RD supply is present on customer interface board PC14.

4
Off Indicates +24 volts dc RD supply is not present on customer interface board PC14.
5 On Input signal On from robot for shielding gas.
Off Input signal Off from robot for no shielding gas.
6 On Input signal On from robot to energize contactor.
Off Input signal Off from robot to not energize contactor.
7 On Input signal On from robot for jog retract.
Off Input signal Off from robot for no jog retract.
On Input signal On from robot for jog advance.
8
Off Input signal Off from robot for no jog advance.
On Indicates automatic configuration Bit D is set.
9
Off Indicates automatic configuration Bit D is not set.
On Input signal On for RPS-C.
10
Off Input signal Off for RPS-C.
On Input signal On for RPS-B.
11
Off Input signal Off for RPS-B.
12 On Indicates remote program A selected.
Off Indicates remote program A not selected.
13 On Input signal On from peripheral for touch sensor.
Off Input signal Off from peripheral for no touch sensor.
On Indicates automatic configuration Bit B is set.
14
Off Indicates automatic configuration Bit B is not set.
On Indicates automatic configuration Bit A is set.
15
Off Indicates automatic configuration Bit A is not set.
On Indicates automatic configuration Bit C is set.
16
Off Indicates automatic configuration Bit C is not set.
On Input signal On from relay CR4 for wire stuck in weld joint.
17
Off Input signal Off from relay CR4 for wire not stuck in weld joint.
On Input signal On from relay CR6 for flow (shielding gas or coolant) present.
18
Off Input signal Off from relay CR6 for flow (shielding gas or coolant) not present.
On Input signal On from relay CR5 for arc detect.
19
Off Input signal Off from relay CR5 for no arc detect.
20 On Input signal On from relay CR2.
Off Input signal Off from relay CR2.
On Input signal On from relay CR1 for welding power source ready and no detected errors present.
21 Off Input signal Off from relay CR1 for welding power source not ready, detected errors are present, or unit
is in Setup or Control mode.
22 On Input signal On from peripheral for flow switch.

Off Input signal Off from peripheral for no flow switch.
OM-203 860 Page 25

23 On Input signal On from peripheral for jog advance.

Off Input signal Off from peripheral for no jog advance.
24 On Input signal On from peripheral for jog retract.
Off Input signal Off from peripheral for no jog retract.
On Input signal On from peripheral for shielding gas purge.
25
Off Input signal Off from peripheral for no shielding gas purge.
On Input signal On for touch sensor.
26
Off Input signal Off for no touch sensor.
OM-203 860 Page 26

4-10. Motor Board PC13 Diagnostic LED’s
1 Motor Board PC13
1 for board location).
LED2 LED1
Reinstall front control panel after
checking diagnostic LED’s.
LED4
LED3
LED6
LED7 LED8 LED5
Front Control
Panel Removed
Front View
177 288 / 802 995
OM-203 860 Page 27

4-11. Diagnostic LED’s On Motor Board PC13
1 On Indicates motor reverse relay is energized.

Off Indicates motor reverse relay is not energized.
2 On Indicates bus voltage is present.
Off Indicates bus voltage is not present.
3 On Indicates microprocessor is operational.
Off Indicates microprocessor is not operational.
4 On Indicates tachometer feedback signal is present.
Off Indicates tachometer feedback signal is not present.
5 On Indicates +5 volts dc is present on motor board PC13.
Off Indicates +5 volts dc is not present on motor board PC13.
6 On Indicates +15 volts dc is present on motor board PC13.
Off Indicates +15 volts dc is not present on motor board PC13.
7 On Indicates auxiliary forward signal is present.
Off Indicates auxiliary forward signal is not present.
8 On Indicates auxiliary output signal is present.
Off Indicates auxiliary output signal is not present.
OM-203 860 Page 28

4-12. Troubleshooting
Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position (see Section 2-11).
inoperative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-11)).
Check for proper input power connections (see Section 2-11).
Check fuse F1, and replace if necessary (see Section 4-3).
Check for proper jumper link position (see Section 2-11).
No weld output; Power switch pilot light Check, repair, or replace remote control.
on; fan on; meter display On.
Unit overheated. Allow unit to cool with fan On (see Section 2-2).
Check voltmeter/ammeter Help displays.
Unit overheated. Allow unit to cool with fan On (see Section 2-2).
Have Factory Authorized Service Agent check control board PC1.
Unit provides only maximum or mini- Have Factory Authorized Service Agent check control board PC1.
mum weld output.
Erratic or improper weld output. Use proper size and type of weld cable (see Section 2-9).
Clean and tighten all weld connections.
Have Factory Authorized Service Agent check control board PC1 and/or SCR in main rectifier.
Fan not operating. Note: fan runs only Check for and remove anything blocking fan movement.
when cooling is necessary.
Have Factory Authorized Service Agent check fan motor.
OM-203 860 Page 29

Notes
OM-203 860 Page 30

SECTION 5 – ELECTRICAL DIAGRAM
. For Primary Circuit Diagram Portion, refer to Circuit Diagram

located inside wrapper of welding power source.
207 810
Figure 5-1. Circuit Diagram For Welding Power Source

OM-203 860 Page 31
Figure 5-2. Circuit Diagram For Interface Module
OM-203 860 Page 32

207 811
OM-203 860 Page 33

Figure 5-3. Circuit Diagram For Microprocessor Board PC11
OM-203 860 Page 34
191 838
OM-203 860 Page 35

Figure 5-4. Circuit Diagram For Motor Board PC13
OM-203 860 Page 36
177 289-A
OM-203 860 Page 37

Figure 5-5. Circuit Diagram For Interface Board PC12 (Part 1 of 2)
OM-203 860 Page 38

191 843-A (Part 1 of 2)
OM-203 860 Page 39

Figure 5-6. Circuit Diagram For Interface Board PC12 (Part 2 of 2)
OM-203 860 Page 40

191 843-A (Part 2 of 2)
OM-203 860 Page 41

Figure 5-7. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3)
OM-203 860 Page 42

Pensar 86147s03 (Part 1 of 3)
OM-203 860 Page 43

OM-203 860 Page 44

OM-203 860 Page 45

OM-203 860 Page 46

OM-203 860 Page 47

191 531
Figure 5-10. Circuit Diagram For Power Distribution Board PC20
OM-203 860 Page 48

Notes
OM-203 860 Page 49

SECTION 6 – PARTS LIST
. Hardware is common and not
23
available unless listed.
19 (Fig.6–4)
21
20
3
16 17 18
15
13 14
12
10 11
4
9
8
7
6
24
5
28
29
39
27
4
2
30
1
26
31 (Fig.6–2)
25
32 (Fig.6–3)
23
34
38
33
40
35
36
37
802 994-A
Figure 6-1. Main Assembly
OM-203 860 Page 50

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 6-1 Main Assembly

. . . 1 . . . . . . . . . . . . +179 432 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 179 431 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 164 699 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 162 816 . . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . . . . . . . . . 162 820 . . BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 162 830 . . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 177 279 . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 604 536 . . SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . Z1 . . . . 166 364 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . HD1 . . . . 168 829 . . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CR6 . . . . 160 966 . . CONTACTOR, def prp 25A 2P 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 173 605 . . BRACKET, mtg contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . C21-23 . . 163 906 . . CAPACITOR, 50 and 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 14 . . . . . T2 . . . . 159 042 . . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . . . . . . . . . . . . 1
. . . 14 . . . . . T2 . . . . 159 041 . . TRANSFORMER, control 50VA 24V 200/230/460 (60Hz) . . . . . . . . . . . . . . 1
. . . 14 . . . . . T2 . . . . 159 043 . . TRANSFORMER, control 50A 24V (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . TE1 . . . . 159 244 . . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 601 835 . . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . 17 . . . . . . . . . . . . . 038 887 . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . 601 835 . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . 038 618 . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 18 . . . . . . . . . . . . . 159 034 . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . Fig 6-5 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . F1 . . . *156 065 . . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . W . . . . . 160 793 . . CONTACTOR, def prp 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 134 464 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . 163 359 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . C1 . . . . 182 661 . . CAPACITOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 163 535 . . . . CAPACITOR, elctlt 16000uf 60VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . R6 . . . . 140 002 . . . . RESISTOR, WW fxd 10W 500 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 162 817 . . . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 182 660 . . . . BUS BAR, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . T1 . . . . 189 835 . . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 166 442 . . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . . . . . . . . . . . . 166 441 . . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 172 309 . . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . . . . . . . . . . . . 172 308 . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 172 427 . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . . . . . . . . . . . . 172 426 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . TP1,2 . . . 175 405 . . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . TP4,5 . . . 168 891 . . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG13 . . 189 873 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC13 . . . 189 874 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG6 . . . 168 847 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 168 845 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-203 860 Page 51

Item Dia. Part
Figure 6-1 Main Assembly (Continued)

. . . 30 . . . . . . . . . . . . . 161 294 . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . . . Fig 6-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . SR1 . . . . 192 672 . . RECTIFIER, SCR main (Fig 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . 115 094 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG7 . . . 152 249 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC7 . . . . 168 846 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 010 467 . . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . R7 . . . ♦114 808 . . RESISTOR, WW fxd 375W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 204 069 . . ELECTRONICS BOX (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . PC2 . . . . 177 909 . . . . CIRCUIT CARD ASSY, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . PC12 . . . 191 841 . . . . CIRCUIT CARD ASSY, weld interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . PC11 . . . 202 115 . . . . CIRCUIT CARD ASSY, processor w/prom . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . PC1 . . . . 207 247 . . . . CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . CR3 . . . . 052 964 . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . T11 . . . . 204 979 . . TRANSFORMER, control 200VA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . CR5 . . . . 006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Part of Option 043 286 Additional Resistor

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-203 860 Page 52

7
6 7
10
6 7
11
12
4
13
3
14
2
15
16
17
1
18
19
21 20
32
31
22
30
29
23
28
27
26
24
25
802 997-A
Figure 6-2. Panel, Front w/Components
OM-203 860 Page 53

Item Dia. Part
Figure 6-2 Panel, Front w/Components (Fig 6-1 Item 31)
... 1 . . . . . . . . . . . . . 203 630 .. ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . CB1,2 . . . 093 995 .. CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . RC9 . . . . 604 176 .. RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 204143 .. PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . POS . . . 181 245 .. TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 . . . C2,4,5 . . . 128 750 .. CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 8 . . . . . . . . . . . . . 161 303 .. SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . . . . . . . . . . . . 3
... 10 . . . . NEG . . . 181 246 .. TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . 162 891 .. LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . +172 587 .. COVER, stud output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 160 935 .. CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 14 . . . . . . . . . . . . . 038 887 .. STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 204 067 .. SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . PC13 . . . 209 249 .. CIRCUIT CARD ASSY, 115V motor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . PC20 . . . 191 533 .. CIRCUIT CARD ASSY, power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . PC22 . . . 200 073 .. CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . PC17 . . . 177 290 .. DISPLAY, LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . PC15 . . . 182 998 .. CIRCUIT CARD ASSY, switch board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . . . . . . . . . . 091 772 .. STAND-OFF, NO 6-32 x .625 LG .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 22 . . . . . . . . . . . . . 203 628 .. PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . 144 842 .. ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 24 . . . RC70 . . . 201 058 .. CONN, rect 72 pin assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 25 . . . . . S2 . . . . 159 039 .. SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . . RC21 . . . 200 082 .. CONN, circ 97/met 4 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 27 . . . CB11 . . . 011 991 .. CIRCUIT BREAKER, man reset 1P 1.5A 250V . . . . . . . . . . . . . . . . . . . . . . . 1
... 28 . . . PC19 . . . 134 560 .. CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . RC8 . . . . 200 589 .. CONN, circ 97/met 10 skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 30 . . . PC21 . . . 200 077 .. CIRCUIT CARD ASSY, robot interface filter hf . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . RC25 . . . 200 591 .. CONN, circ 97/met 11 skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 32 . . . PC14 . . . 191 570 .. CIRCUIT CARD ASSY, customer interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-203 860 Page 54

2 3
4
5
Figure 6-3. Rectifier, SCR Main SR1 802 351
Item Dia. Part

Figure 6-3 Rectifier, SCR Main (Fig 6-1 Item 32)
SR1 192 672
. . . 1 . . . . C7-12 . . . . 048 420 . . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . . . 191 989 . . BAR, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 188 691 . . CLAMP, thyristor rectifier 5.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 4 . . . . . . . . . . . . . . . 188 839 . . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 5 . . . SCR1-6 . . . 161 668 . . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 6 . . . . . . . . . . . . . . . 166 667 . . CLAMP, spring thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG1 . . . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . TP3 . . . . . 192 673 . . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . TP6 . . . . . 192 674 . . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-203 860 Page 55

Item Dia. Part
Figure 6-4 Panel, Rear w/Components (Fig 6-1 Item 19)
. . . 1 . . . . . . . . . . . . . . . 173 283 .. CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . 180 165 .. BLADE, fan 14 in 3wg 28deg .375 bore CCW . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 162 807 .. PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 168 343 .. HINGE, door primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . +162 818 .. DOOR, access primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 168 384 .. LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 602 177 .. SCREW, set .250-20 x .250knrlpt sch stl . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 124 274 .. BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . R3 . . . . . . 114 808 .. RESISTOR, WW fxd 375W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . FM . . . . . 116 190 .. MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 010 467 .. CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 194 905 .. KIT, blocking diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3
. Hardware is common and not 4
available unless listed. 5
6
2
1
11
7
10 9
Ref. 802 798 / 800 707-A
Figure 6-4. Panel, Rear w/Components
OM-203 860 Page 56

Effective January 1, 2001
(Equipment with a serial number preface of “LB” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
Spoolguns)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.
4. 6 Months — Batteries In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,
5. 90 Days — Parts and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
* MIG Guns/TIG Torches Warranty provides specific legal rights, and other rights may
* Induction Heating Coils and Blankets be available, but may vary from province to province.
miller_warr 10/01
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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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
European Headquarters –
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
Contact the Delivering Carrier for: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA  2002 Miller Electric Mfg. Co. 1/02

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OM-203 860A

Arc Welding Power Source

Visit our website at

Miller offers a Technical

1-1. Symbol Usage

1-2. Arc Welding Hazards

OM-203 860 Page 1

OM-203 860 Page 2

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

FALLING UNIT can cause injury.

STATIC (ESD) can damage PC boards.

1-4. Principal Safety Standards

OM-203 860 Page 3

OM-203 860 Page 4

1-1. Signification des symboles

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des

1-2. Dangers relatifs au soudage à l’arc

UN CHOC ÉLECTRIQUE peut tuer.

OM-203 860 Page 5

LE SOUDAGE peut provoquer un

OM-203 860 Page 6

Risque D’INCENDIE OU DES ORGANES MOBILES peuvent

LES CHAMPS MAGNÉTIQUES peuvent

OM-203 860 Page 7

1-5. Information sur les champs électromagnétiques

OM-203 860 Page 8

Amperes Input at Rated Load Output, 50 or 60 Hz,

2-2. Duty Cycle And Overheating

fan runs. Wait fifteen minutes for

100% Duty Cycle

OM-203 860 Page 9

va_curve1 – 4/95 – 171 224 / 171 225 / 171 226

2-4. Selecting A Location

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Depth 35-3/4 in (908 mm)

B 1-1/4 in (32 mm)

D 1-3/16 in (30 mm)

E 7/16 in (11 mm) Dia

450 Amp 384 lb (174 kg)

2-7. 115 VAC Receptacle And Circuit Breakers

Ref. 800 166-D

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2-9. Weld Output Terminals And Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

Y Do not use worn, dam-

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

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Reference: 1999 National Electrical Code (NEC)

50 Hertz Models 450 Amp Model

Reference: 1999 National Electrical Code (NEC)