Miller PipeWorx 400 Owner'S Manual Download Page 99

Page: 99 / 120

OM-236 891 Page 95

Quantity

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 10-1. Main Assembly

Model

907 382 907 384

+233480

PANEL,REAR

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

CB2

093995

SUPPLEMENTARY PRO,MAN RESET 1P 15A 250VAC FRICT 1

. . .

. . . . . .

. .

. . . .

PC11

244471

CIRCUIT CARD ASSY,PS/FEEDER INTERFACE

. . .

. .

. . . . .

. .

. . . . . . . . . . . .

. . . .

228036

VALVE, 24VAC 1WAY .750

−

14 THD 2.0MM ORF 100 PSI

. . .

. . . . . . . . . . . . . .

. .

. . . . .

. . . .

236638

HOSE,NPRN BRD NO 1 X .187 ID X 40.000

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . .

. . . .

220805

NUT, 750

−

14 NPS 1.48HEX .41H NYL

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . .

. . . .

010467

CONN,CLAMP CABLE 1.250

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

181181

LABEL,WARNING MATCH INPUT POWER TO VOLTAGE

. . .

. . . . . . . . . . . . . .

. .

. . . .

237163

LABEL,MIG OUTPUT

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

237157

LABEL,CB2

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

238560

LABEL,TIG GAS IN

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

237158

LABEL,TO WIREFEEDER

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

C3, C4,

. . .

C5, C6

192935

CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA

. . . .

. .

. . . . . . .

C3, C4,

. . .

C5, C6

193738

CAPACITOR,ELCTLT 1800 UF 500 VDC CAN 2.52 DIA

. . . .

. .

. . . . . . . . . . . . . .

218004

LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS

. . . . . . . . . . . . . . . . . . . .

. .

. . . .

217040

NUT,NYLON M12 THREAD CAPACITOR MOUNTING

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . .

. . . .

PC4

240621

CIRCUIT CARD ASSY,INTERCONNECTING

. . .

. . . . . .

. .

. . . . . . . . . . . . . . . .

PC4

240623

CIRCUIT CARD ASSY,INTERCONNECTING

. . .

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

185214

BUS BAR,INTERCONNECTING 575

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC10

234712

CIRCUIT CARD ASSY,RELINK 230/460

. . .

. .

. . . . .

. .

. . . . . . . . . . . . . . . . . . . . .

PC10

246406

CIRCUIT CARD ASSY,RELINK BALANCE

. . .

. .

. . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . .

+233486

PANEL,SIDE RH 230/460

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+240841

PANEL,SIDE RH 575

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

237155

LABEL,IMPORTANT INPUT POWER/RELINK CONNECTIONS 1

. . .

. . . . . . . . . . . . . .

. .

222317

LABEL,WARNING MATCH INPUT POWER

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . .

234271

SHEET,INSULATOR SIDE PANEL

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

17 FM1, FM2

222728

FAN,MUFFIN 24VDC 3000 RPM 255 CFM

. . .

. .

. . . . . . . . . . . . . . . . . .

. . . .

233501

BRACKET,FAN

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

L1 180026

INDUCTOR,INPUT

. . .

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

WINDTUNNEL,RH W/CMPNTS (INCLUDES)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . .

030170

BUSHING,SNAP

−

IN NYL .750 ID X 1.000 MTG HOLE

. . .

. . . . . . . . . . . . . .

. . . .

. . . . . .

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025248

STAND

−

OFF,INSUL .250

−

20 X 1.250 LG X .437 THD

. . .

. . . . . . . . . . . . . .

. . . .

. . . . . . .

. . . .

180270

CONTACTOR,DEF PRP 40A 3P 24VAC COIL W/BOXLUG

. . .

. . . . . .

. . . .

. .

. . . .

CT1

233620

XFMR,CURRENT 500 TURN POLARIZED

. . .

. . . . . .

. . . .

. . . . . . . . . . . . . . . .

. . . .

177547

BUSHING,SNAP

−

IN NYL CT

−

MOUNT 1.125 MTG HOLE

. . .

. . . . . . . . . . . . . .

. . . .

. . .

. . . .

010493

BUSHING,SNAP

−

IN NYL .625 ID X .875 MTG HOLE

. . .

. . . . . . . . . . . . . .

. . . .

. . . . . . .

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233462

WINDTUNNEL,RH

. . .

. . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

27 PM1, PM2

240144

KIT,TRANSISTOR IGBT MODULE

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . .

179930

HEAT SINK,POWER MODULE

. . .

. . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

RT1

173632

THERMISTOR,NTC 30K OHM @ 25 DEG C 12.00IN LEAD

. . .

. . . . . .

. . . .

. .

. . . .

SR1

249052

KIT, RECTIFIER, INTEG BRIDGE

. . .

. . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . .

C1, C2

230272

CAPACITOR,POLYP FILM .34 UF 1000 VRMS +/

−

10%

. . .

. .

. . . .

. .

. . . . . . .

C1, C2

230270

CAPACITOR,POLYP FILM .22 UF 1000 VRMS +/

−

10%

. . .

. .

. . . .

. .

. . . . . . . . . . . . . .

L2 233438

INDUCTOR,OUTPUT

. . .

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

L3, L4

233617

INDUCTOR,DI

−

. . .

. .

. . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

218566

GASKET,INDUCTOR MOUNTING E70 FERRITE CORE

. . .

. . . . . . . . . . . . . .

. .

. . . . . .

. . . .

CB1

083432

SUPPLEMENTARY PRO,MAN RESET 1P 10A 250VAC FRICT 1

. . .

. . . . . .

. .

. . . .

RC2

134837

RCPT,STR GRD 2P3W 15A 125V SINGLE *5

−

15R

. . .

. . . . . .

. .

. . . . . . . . . . .

. . . .

170647

BUSHING,SNAP

−

IN NYL 1.312 ID X 1.500 MTG HOLE

. . .

. . . . . . . . . . . . . .

. .

. . . . . . .

. . . .

HD1

168829

TRANSDUCER,CURRENT 1000A MODULE

. . .

. . . . . .

. .

. . . . . . . . . . . . . . . . .

. . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Summary of Contents for PipeWorx 400

Page 1: ...MAW P Welding Multiprocess Welding Description PipeWorx 400 Welding System 230 460 And 575 Volt Models File MIG GMAW Visit our website at www MillerWelds com TIG GTAW Welding Flux Cored FCAW Welding S...

Page 2: ...inue 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 t...

Page 3: ...tector CB2 23 5 7 115 Volts AC Single Receptacle And Supplementary Protector 24 5 8 Lifting Eye On Power Source 25 5 9 Selecting Input Voltage 230 460 Volt Models Only 26 5 10 Electrical Service Guide...

Page 4: ...2 Blowing Out Inside of Unit 74 7 3 Restoring Factory Defaults 75 7 4 Viewing Software Revision 75 7 5 Power Source Calibration Procedure 75 7 6 Removing Right Side Panel and Measuring Input Capacito...

Page 5: ...ds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following eq...

Page 6: ...ums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoli...

Page 7: ...NG PARTS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards...

Page 8: ...ntion During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Healt...

Page 9: ...utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les con...

Page 10: ...ne et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur...

Page 11: ...eur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprim...

Page 12: ...der seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion D L utilisateur est tenu de faire corriger rapidement par un lectricien quali...

Page 13: ...t Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Re...

Page 14: ...OM 236 891 Page 10...

Page 15: ...ric shock by insulating yourself from work and ground Safe3 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes Safe8 2012 05 Use ventilat...

Page 16: ...use or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collection facility Contact your local recycling office or your local distributor for further information Saf...

Page 17: ...ear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Safe38 2012 05 Become trained and read the instructi...

Page 18: ...elded Metal Arc Welding SMAW High Frequency General Increase Line Connection Gas Metal Arc Welding GMAW Three Phase Static Frequency Con verter Transformer Rectifier U0 Rated No Load Voltage Average U...

Page 19: ...nput At Rated Load Output 60 Hz Three Phase KVA KW 230 V 460 V 575 V 230 460 575 230 460 575 Three Phase Stick 400 A 36 Volts DC 100 Duty Cycle 40 400 90 43 9 26 6 22 4 17 5 21 2 22 3 16 1 16 3 16 4 T...

Page 20: ...m 65 lb 30 kg 90 lb 41 kg This equipment is designed for indoor use and is not intended to be used or stored outside D Cooler Specifications Input Power Overall Dimensions Coolant Capacity Weight Pump...

Page 21: ...5 240 110 A Continuous Welding 100 Duty Cycle At 400 Amperes 60 Duty Cycle At 500 Amperes 6 Minutes Welding 4 Minutes Resting 4 4 Stick And TIG Duty Cycle and Overheating Duty Cycle is percentage of 1...

Page 22: ...e present see NEC Article 511 or CEC Section 20 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Line Disc...

Page 23: ...es an amperage range of 0 to 100 based on the Amperage Adjust knob setting The Remote 14 receptacle is factory set to be active in TIG mode only As an option this receptacle may also be enabled in Sti...

Page 24: ...er source front panel the contactor and primary secondary amperage control will function in both TIG and Stick modes 1 User Interface Board 2 Dip Switch Remove feeder and side mount cable hangers from...

Page 25: ...input power and check voltage on input capacitors accord ing to Section 7 6 before proceeding 1 PipeWorx Feeder 2 Operator Interface Board 3 Dip Switch Remove feeder wrapper Move number 1 switch top...

Page 26: ...AC return Connected to chassis common Completes 24 volts AC power supply circuit to feeder SERIAL COMMUNICATION 6 Isolated RS 485 serial communication signal 3 Isolated RS 485 serial communication sig...

Page 27: ...ementary Protector CB2 805 298 A 1 SupplementaryProtector CB2 CB2 protects the 24 volts ac power supply to the wire feeder see Section 5 5 Press button to reset supplementary protector 1 MIG OUTPUT TI...

Page 28: ...tended only for supplying AC power to a PipeWorx cooler Power is available at receptacle RC2 only when the power source is on 2 Supplementary Protector CB1 CB1 protects single 115 volt AC receptacle P...

Page 29: ...ntire welding system as shown with cable hangers cooler with coolant dual feeder and running gear can be lifted with the lifting eye The control cable must be disconnected from the feeder Use of a lif...

Page 30: ...in unit Changing selection is only necessary if selected value does not match available input voltage 2 Relinking Board PC10 In 230 VAC Position 3 Mounting Screws 4 Receptacle RC8 Connection For 230 V...

Page 31: ...than the rating of the circuit protection device All components of the circuit must be physically compatible See NEC articles 210 21 630 11 and 630 12 60 Hz Three Phase Input Voltage V 230 460 575 In...

Page 32: ...OM 236 891 Page 28 5 11 Connecting 3 Phase Input Power Input5 2013 04 Ref 803 766 C 805 146 A Tools Needed 5 16 in L1 L2 L3 1 2 6 L1 7 1 L2 L3 3 4 8 6 9 10 GND PE Earth Ground 3 4 5...

Page 33: ...elief of proper size for unit and input conductors Route conductors cord through strain relief and tighten screws 3 Welding Power Source Grounding Terminal 4 Green Or Green Yellow Grounding Conductor...

Page 34: ...cket to rear of power source and secure with supplied screws Install bushings and chains 15 Handle Bracket 16 Handle 2 17 Tube Cap 4 Install tube caps into ends of handles Remove 5 screws above louver...

Page 35: ...B 805 141 A 1 Bracket 2 Tube Cap 4 3 Cable Holder Tube 2 Install caps in tubes Assemble cable holder tubes to bracket using supplied hardware Place cable holder assembly on top of power source or cart...

Page 36: ...Tape Or Heat Shrink Tubing 3 Center Conductor 10 ga 4 Ring Terminal 1 2 in Opening 1 Tools Needed 3 4 2 Ref 239 780 B 5 15 Connecting Volt Sense Lead And Work Cable To Clamp 805 030 A Tools Needed 1...

Page 37: ...150 2 0 70 2 0 70 2 0 70 2 0 70 2 0 70 3 0 95 3 0 95 200 2 0 70 2 0 70 2 0 70 2 0 70 3 0 95 4 0 120 4 0 120 250 2 0 70 2 0 70 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 2 0 70 2 0 70 3 0 95...

Page 38: ...t 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against...

Page 39: ...f power source and connect 14 socket plug to rear of wire feeder Connect one end of weld cable to weld terminal on rear of power source Connect remaining end of weld cable to wire feeder drive housing...

Page 40: ...rear of power source and connect 14 socket plug to rear of wire feeder Connect one end of weld cable to weld terminal on rear of power source and secure cable in clamp block on rear panel Connect rema...

Page 41: ...ght hand threads Connect customer supplied gas hose 3 Weld Cable Terminal 4 Jumper Weld Cable From Right Side Drive Assembly Dual Model Only 5 Weld Cable 6 Drive Assembly 7 Drive Assembly Rotation Kno...

Page 42: ...236 891 Page 38 5 21 Gun Trigger Receptacle 805 154 A 1 Left Gun Trigger Receptacle RC2 2 Right Gun Trigger Receptacle RC3 Dual Model Only Connect gun trigger plug to appropriatereceptacle on feeder 1...

Page 43: ...rolls To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Tighten knob so wire does not slip Do not overtighten If...

Page 44: ...o provide an accurate voltage feedback signal to the welding system Use of this lead is critical for stable welding performance 5 Wire Feeder 6 Workpiece This arrangement is an ideal setup for support...

Page 45: ...leads being directly in the current flow path of the welding arc Interaction between welding circuits will affect voltage drop in the workpiece The voltage drop across the workpiece will not be measu...

Page 46: ...ically compensates for work cable voltage drop when connected to the welding power source Do not coil excess cables Use cables that are the appropriate length for the application Avoid coupling the vo...

Page 47: ...rkpiece 5 Electrode Holder 6 Volt Sense Lead Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 5 25 Typical Connection Diagram For Stick SMAW Equipment 1 2 3 5 4 6...

Page 48: ...Cable 5 Workpiece 6 TIG Torch 7 Volt Sense Lead 8 Remote Foot Control Optional Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 5 26 Typical Connection Diagram Fo...

Page 49: ...r Supplied 4 TIG Weld Cable 5 Work Weld Cable 6 Workpiece 7 TIG Torch 8 Volt Sense Lead 9 Remote Foot Control Optional Attach volt sense lead to work clamp and attach work clamp as close to arc as pos...

Page 50: ...oler 5 TIG Weld Cable 6 Coolant Return Hose 7 Work Weld Cable 8 Workpiece 9 TIG Torch 10 Volt Sense Lead 11 Remote Foot Control Optional Attach volt sense lead to work clamp and attach work clamp as c...

Page 51: ...zes can be used in the process Gas Type Selection of shielding gas being used in an application C8 C15 Argon 8 15 CO2 C20 Argon 20 CO2 C25 Argon 25 CO2 100 CO2 C2 Argon 2 CO2 98 2 Ox Argon 2 O2 TRI H...

Page 52: ...gic refers to the unit s ability to use preprogrammed parameters to determine the actual pulse settings of Peak Amperage Background Amperage Pulse Frequency and Pulse Width at any specific wire feed s...

Page 53: ...ry Location Buttons 1 4 6 Stick Process Select Button 7 Stick Electrode Type Select Button 8 Ammeter Display 9 Amperage Adjust Knob 10 TIG Process Select Button 11 TIG Starting Method Select Button 12...

Page 54: ...e slot and used for storing and retrieving operator settings providing custom MIG type weld process data and loading firmware updates to the unit If the power source has multiple users each user may u...

Page 55: ...release c Close memory card access cover 2 Memory Card Removal a Lift and hold memory card access cover open b Push in and release memory card to eject card c Grasp memory card and remove from slot d...

Page 56: ...button for two seconds The Amperage display will show the DIG setting with the right most decimal point illuminated The default value for DIG is 40 b Rotate the Amperage knob to adjust the DIG setting...

Page 57: ...ly the available gas selections in one particular column of the gas table based on the selected MIG process and WIRE TYPE and WIRE DIAMETER The text illuminates when any MIG process is selected except...

Page 58: ...Stick Process Selection Setup Example Only illuminated controls can be changed or adjusted 1 Stick Process Active 2 EXX10 Electrode Type Selected 3 Amperage Setting 350A 4 Memory Location 1 Active 1 2...

Page 59: ...6 4 TIG Process Selection Setup Example Only illuminated controls can be changed or adjusted 1 TIG Process Active 2 HF Start Method Selected 3 Amperage Setting 350A 4 Memory Location 2 Active 1 2 3 4...

Page 60: ...1 Only illuminated controls can be changed or adjusted 1 MIG Process Active 2 Carbon Steel Wire Type Selected 3 0 035 Wire Diameter Selected 4 C8 C15 Gas Type Selected 5 Trigger Select On 6 Side Sele...

Page 61: ...y illuminated controls can be changed or adjusted 1 Pro Pulse MIG Process Active 2 Stainless Steel Wire Type Selected 3 0 035 Wire Diameter Selected 4 TRI H Gas Type Selected 5 Trigger Select On 6 Sid...

Page 62: ...Arc Length Adjust Knob 4 Right Side Controls Select Button 5 ACCU POWER Indicator Optional 6 Wire Feed Speed Display 7 Wire Feed Speed Adjust Knob 8 MPM IPM Indicator 9 Memory Card Indicator 10 MIG P...

Page 63: ...to 3 0 in 0 1 increments with 0 as nominal depending on the type of MIG process selection Rotating the knob clockwise increases volts arc length and counter clockwise decreases volts arc length Volts...

Page 64: ...show the set wire length for a short time after making any desired adjustment If no further changes are made to the wire length after one second the unit will resume the count down display Jog speed c...

Page 65: ...w times are automatic ally calculated as follows Preflow Preflow is only active when in the HF start mode For TIG the preflow time is set to 0 1 seconds when in the standard configuration For wire pro...

Page 66: ...e Purge button 5 Adjust preflow time to desired value by rotate the Wire Feed Speed knob Available selections include Std and numeric values from 0 9 to 10 0 seconds If Trigger Select is enabled there...

Page 67: ...9 Wire Feeder Left Side Active Setup Example Only illuminated controls can be changed or adjusted 1 Left Side Controls Active 2 MIG Process Selected 3 Trigger Hold Off 4 Memory Location 1 Active 4 3 1...

Page 68: ...eeder Right Side Active Setup Example Dual Feeder Only Only illuminated controls can be changed or adjusted 1 Right Side Controls Active 2 Pulse Process Selected 3 Trigger Hold On 4 Memory Location 2...

Page 69: ...OM 236 891 Page 65 6 11 Wire Feeder Non MIG Setup Example Only illuminated controls can be changed or adjusted 1 Non MIG Process Selected 2 Memory Location 3 Active 2 1 252 614 A...

Page 70: ...re Feeder Timed Purge Example Only illuminated controls can be changed or adjusted 1 Purge And Trigger Hold Buttons Pressed Simultaneously 2 Purge Time Setting Adjustment Knob 3 Purge Time Remaining D...

Page 71: ...y illuminated controls can be changed or adjusted 1 Jog And Trigger Hold Buttons Pressed Simultaneously 2 Jog Feet Adjustment Knob 3 Jog Feet Remaining Display 4 Jog Wire Feed Speed Adjustment Knob 5...

Page 72: ...100 CO2 040 1 0 100 250 w 175 Nominal 2 5 6 4 w 4 4 Nominal 3 0 to 3 0 w zero Nominal C8 C15 040 1 0 100 250 w 175 Nominal 2 5 6 4 w 4 4 Nominal 3 0 to 3 0 w zero Nominal C20 040 1 0 100 250 w 175 Nom...

Page 73: ...780 w 300 Nominal 2 5 19 8 w 7 6 Nominal 3 0 to 3 0 w zero Nominal C20 045 1 1 75 500 w 250 Nominal 1 9 12 7 w 6 4 Nominal 3 0 to 3 0 w zero Nominal C8 C15 ProPulse Steel Welding In Position 035 0 9...

Page 74: ...35 0 9 100 350 w 200 Nominal 2 5 8 9 w 5 1 Nominal 3 0 to 3 0 w zero Nominal Tri A 040 1 0 100 300 w 175 Nominal 2 5 7 6 w 4 4 Nominal 3 0 to 3 0 w zero Nominal C2 040 1 0 100 300 w 175 Nominal 2 5 7...

Page 75: ...ero Nominal Tri H 035 0 9 100 780 w 250 Nominal 2 5 19 8 w 6 4 Nominal 3 0 to 3 0 w zero Nominal Tri A 040 1 0 75 780 w 300 Nominal 1 9 19 8 w 7 6 Nominal 3 0 to 3 0 w zero Nominal C2 040 1 0 75 780 w...

Page 76: ...al 2 5 19 8 w 5 1 Nominal 3 0 to 3 0 w zero Nominal Tri A 040 1 0 100 780 w 175 Nominal 2 5 19 8 w 4 4 Nominal 3 0 to 3 0 w zero Nominal C2 040 1 0 100 780 w 175 Nominal 2 5 19 8 w 4 4 Nominal 3 0 to...

Page 77: ...r hand control if a remote control is connected Hold electrode to workpiece for 1 2 seconds and slowly lift electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present...

Page 78: ...ble Labels Weld Terminals nl Weld Cable l Cracked Parts n 14 Pin Cord n Gas Hose and Fittings n Gun Cable l Cracked Electrode Holder Parts l Cracked Torch Body Every 6 Months Or Inside Unit Drive Roll...

Page 79: ...open b Insert memory card into slot push card all the way into slot and then release c Close memory card access cover d Power source will display CAL 4 Calibrate MIG voltage as follows a Connect voltm...

Page 80: ...a Connect shorting cable from STICK stud front left to Work stud front center b Attach clamp on ammeter around shorting cable c Press memory 4 button on the power source front panel Amperage should no...

Page 81: ...tage across the screw terminals on PC10 as shown until voltage drops to near 0 zero volts Proceed with job inside unit Reinstall right side panel when finished Tools Needed 5 16 in Ref 805 142 A Ref 8...

Page 82: ...0 3 Voltmeter Measure the dc voltage across the screw terminals on PC10 as shown until voltage drops to near 0 zero volts Proceed with job inside unit Reinstall right side panel when finished Tools Ne...

Page 83: ...actory Authorized Service Agent Every 3 Months Clean coolant strainer Severe conditions may require more frequent cleaning continuous use high low temperatures dirty environment etc Failure to properl...

Page 84: ...g and slide cooler drawer out 3 Coolant Filter Unscrew housing to clean filter and housing Changing coolant Drain coolant by tipping unit forward Fill with clean water and run for 10 minutes Drain and...

Page 85: ...ning If this code appears on the display contact the nearest Factory Authorized Service Agent H11 Primary Bus Capacitor Voltage Imbalance Indicates primary power circuit is malfunctioning If this code...

Page 86: ...s attempted to a locked card This refers to the physical switch on the memory card Unlock the memory card and try again Try a different memory card Remove card or press any button to clear error If th...

Page 87: ...sense lead is separated from weld cables S Be sure gun angle during welding is straight in to 15 degrees back at joint S Follow recommended settings in Operation section of manual to select a startin...

Page 88: ...Unit overheated Allow unit to cool with fan On see Section 4 4 Check voltmeter ammeter Help displays Erratic or improper weld output Use proper size and type of weld cable see Section 5 16 Clean and t...

Page 89: ...Authorized Service Agency check drive motor or motor control board PC1 Motor runs slowly Check for correct input voltage Wire feeder displays light up feeder jogs purges but unit is inoperative Check...

Page 90: ...OM 236 891 Page 86 SECTION 8 ELECTRICAL DIAGRAMS Figure 6 1 Circuit Diagram For Welding Power Source...

Page 91: ...OM 236 891 Page 87 254 310 B...

Page 92: ...OM 236 891 Page 88 Figure 6 2 Circuit Diagram For Single Or Dual Wire Feeder...

Page 93: ...OM 236 891 Page 89 236 220 E...

Page 94: ...OM 236 891 Page 90 Figure 6 3 Circuit Diagram For Cooler 238 662 B...

Page 95: ...OM 236 891 Page 91 Figure 6 4 Flow Diagram For Cooler Pump Filter Radiator Flow Indicator Tank Torch...

Page 96: ...ces of Direct High Frequency Radiation 1 High Frequency Source welding power source with built in HF or separate HF unit 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources of Conducti...

Page 97: ...it every 50 ft 15 m 6 Water Pipes and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines...

Page 98: ...3 4 5 9 10 11 80 14 17 18 19 20 21 34 31 23 33 24 25 26 27 28 29 30 36 37 40 39 38 41 42 35 43 75 76 77 78 43 44 45 46 47 63 62 48 50 52 51 53 54 55 56 57 59 60 61 58 65 69 64 66 82 83 67 71 72 74 73...

Page 99: ...ANEL 1 1 17 FM1 FM2 222728 FAN MUFFIN 24VDC 3000 RPM 255 CFM 2 2 18 233501 BRACKET FAN 1 1 19 L1 180026 INDUCTOR INPUT 1 1 WINDTUNNEL RH W CMPNTS INCLUDES 1 1 20 030170 BUSHING SNAP IN NYL 750 ID X 1...

Page 100: ...12810 LABEL ON OFF W SYMBOLS 1 1 WINDTUNNEL LH W CMPNTS INCLUDES 1 1 61 233910 HEAT SINK POWER MODULE 1 1 62 D1 D2 D3 D4 249053 KIT DIODE ULTRA FAST RECOVERY 4 4 63 233490 BUS BAR DIODE 2 2 64 233461...

Page 101: ...88 PC2 244438 CIRCUIT CARD ASSY INVERTER CONTROL W PROGRAM 1 198122 STAND OFF SUPPORT PC CARD 250W POST LOCK 10 10 89 236299 CHOKE COMMON MODE 1 1 236770 BRACKET MTG XFMR ASSY INCLUDES 1 1 90 233478 B...

Page 102: ...IATOR INCLUDES 1 6 232424 RADIATOR HEAT EXCHANGER 1 7 231341 PLENUM AIR 1 8 213072 FAN MUFFIN 115V 60HZ 3400 RPM 6 378 MTG HOLES 1 9 236813 BASE W PEM STUDS 1 10 236845 SIDE COOLER BASE 2 11 236846 PA...

Page 103: ...OUT 1 204604 LABEL COOLANT IN 1 23 236815 BRACKET W FILTER INCLUDES 1 24 236816 BRACKET TANK TOP 1 25 166564 FILTER IN LINE LOW PROFILE 100 SCREEN 3 8 HOSE BAR 1 26 178461 BRACKET FILTER 1 27 239494...

Page 104: ...ware is common and not available unless listed 805 152 A 1 2 3 4 5 7 8 9 1011 12 13 12 11 10 14 15 16 6 25 26 27 17 18 19 21 22 24 40 28 29 32 33 34 36 37 38 39 23 42 41 20 30 35 31 Figure 10 5 Figure...

Page 105: ...ER INCLUDES 1 20 PC2 246618 CIRCUIT CARD ASSY UI W PROGRAM FEEDER 1 21 252615 OVERLAY SINGLE FEEDER 1 22 234501 BEZEL FEEDER 1 23 213134 KNOB ENCODER 1 670 DIA X 250 ID PUSH ON W SPRING 2 24 233560 PA...

Page 106: ...IN NYL 750 ID X 1 000 MTG HOLE 2 41 239737 RECEPTACLE BANANA JACK BLK 10 32 BINDING POST 1 42 238498 ENCLOSURE REAR SINGLE FEEDER 1 074481 LABEL LEFT 1 106410 LABEL TO POWER SOURCE 1 215467 LABEL VOL...

Page 107: ...on and not available unless listed 805 150 A 1 3 2 4 5 6 7 8 7 6 5 9 10 11 12 16 17 18 19 21 26 25 24 27 28 32 33 35 36 37 40 42 44 43 38 38 39 39 15 23 22 20 34 29 14 13 13 30 Figure 10 5 31 Figure 1...

Page 108: ...0 PANEL FRONT 1 24 PLUG ASSY TRIGGER LH INCLUDES 1 PLG17 115093 HOUSING PLUG SKTS SERVICE KIT 1 RC2 048282 RCPT W SKTS SERVICE KIT 1 25 PLUG ASSY REMOTE INCLUDES 1 RC4 222857 HOUSING PLUG SKTS SERVICE...

Page 109: ...IONARY STATIC WIRE FE 1 PANEL ASSY PCB SUPPORT INCLUDES 1 42 236556 PANEL PC BOARD SUPPORT 1 198122 STAND OFF SUPPORT PC CARD 250W POST LOCK 500 7 43 010494 BUSHING SNAP IN NYL 1 375 ID X 1 750 MTG HO...

Page 110: ...4 2 172 075 Carrier Drive Roll W Components 4 3 149 962 Spacer Carrier Drive Roll 4 4 149 486 Pin Rotation Arm Rocker 2 5 132 750 Arm Pressure 2 6 150 520 Spacer Flat Stl 257 Id X 619 Od X 105 2 7 13...

Page 111: ...her Stripping Adh 125 X 375 1 23 167 387 Spacer Locating 2 24 168 825 Drive Pinion 1 25 133 308 Ring Retaining Ext 375 Shaft X 025Thk 1 26 134 834 Hose Sae 187 Id X 410 Od order by ft 2 Ft 0 6 m 27 14...

Page 112: ...in 1 1 1 2 mm 150 994 149 519 151 027 053 697 151 053 132 957 052 in 1 3 1 4 mm 150 994 149 519 151 028 053 698 151 054 132 956 1 16 in 062 in 1 6 mm 150 995 149 520 151 029 053 699 151 055 132 955 0...

Page 113: ...OM 236 891 Page 109 Hardware is common and not available unless listed 805 302 b 12 1 3 4 7 8 9 9 10 11 2 5 6 5 Figure 10 6 Running Gear...

Page 114: ...LESS 2 0 X 31 BRIGHT ZINC PLD 2 8 234359 RACK WHEEL ASSY RUNNING GEAR 1 9 602250 WASHER FLAT 812IDX1 469ODX 134T STL PLD ANSI 750 4 10 121614 RING RTNG EXT 750 SHAFT X 085 THK E STYLE PLD 2 11 163463...

Page 115: ...TERMS 1 3 238111 CABLE WELD 31 FT 2 0 W TERMS 1 3 238112 CABLE WELD 56 FT 2 0 W TERMS 1 4 238432 CLAMP STRAIN RELIEF 2 2 5 238263 COVER CABLE 28 FT BLACK 1 5 238264 COVER CABLE 53 FT BLACK 1 6 210253...

Page 116: ...s Item No Figure 10 8 Cable Hanger Assembly Quantity 1 285304 BRACKET CABLE HOLDER W EDGE TRIM 1 2 238611 CAP TUBE 865 OD 4 3 236826 TUBE CABLE HOLDER 2 To maintain the factory original performance of...

Page 117: ...OM 236 891 Page 113 805 318 A Hardware is common and not available unless listed 8 1 2 3 4 5 6 7 9 10 13 11 12 14 15 Figure 10 9 Feeder Cart...

Page 118: ...OD X 2 000 WIDE X 750 BORE 2 9 602250 WASHER FLAT 812ID X 1 469OD X 134T STL PLD 4 10 121614 RING RTNG EXT 750 SHAFT X 085 THK E STYLE PLD 2 11 234545 SHELF LOWER FEEDER CART 1 12 123557 CASTER SWVL...

Page 119: ...lies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard...

Page 120: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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