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miller_warr 2010

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Effective January 1, 2010

(Equipment with a serial number preface of MA or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY 

 Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its

original retail purchaser that new Miller equipment sold after the

effective date of this limited warranty is free of defects in material

and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or replace

any warranted parts or components that fail due to such defects in

material or workmanship. Miller must be notified in writing within

thirty (30) days of such defect or failure, at which time Miller will

provide instructions on the warranty claim procedures to be

followed.

Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to an

International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules

2. 3 Years — Parts and Labor

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders

* Smith 30 Series Flowgauge and Flowmeter

Regulators (No Labor)

* Transformer/Rectifier Power Sources

* Water Coolant Systems (Integrated)

3. 2 Years — Parts

* Auto-Darkening Helmet Lenses (No Labor)

4. 1 Year — Parts and Labor Unless Specified

* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options

(NOTE: Field options are covered for the remaining

warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.)

* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)

* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and

Electronic Controls/Recorders

* Load Banks
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers

* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Work Stations/Weld Tables (No Labor)

5. 6 Months — Parts

* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)

6. 90 Days — Parts

* Accessory (Kits)

* Canvas Covers

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

* M-Guns

* MIG Guns and Subarc (SAW) Guns

* Remote Controls and RFCS-RJ45

* Replacement Parts (No labor)

* Roughneck Guns

* Spoolmate Spoolguns

Miller’s True Blue

®

 Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work

station table tops and welding curtains, or parts that

fail due to normal wear. (Exception: brushes and

relays are covered on all engine-driven products.)

2. Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are

covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable

and necessary maintenance, or equipment which has

been used for operation outside of the specifications for

the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4) payment

of or credit for the purchase price (less reasonable depreciation

based upon actual use) upon return of the goods at customer’s risk

and expense. Miller’s option of repair or replacement will be F.O.B.,

Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized

service facility as determined by Miller. Therefore no

compensation or reimbursement for transportation costs of any

kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,

MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,

CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR

FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO

ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS

EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.
In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein, and

to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

but may vary from province to province.

 

Содержание OM-246 466B

Страница 1: ...ription MIG GMAW Welding RMD Modified Short Circuit Pulsed MIG GMAW P TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source Multiprocess Welding File Pipe Welding Products Visit our website at...

Страница 2: ...ntinue 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...

Страница 3: ...case Feeder 17 3 11 Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs Suitcase Feeder 18 3 12 Rear Panel Receptacles And Supplementary Protectors 20 3 13 Peripheral Receptacle...

Страница 4: ...e Wire Feeder Issues 49 7 3 Diagnostics 50 7 4 Removing Cover and Measuring Input Capacitor Voltage 52 7 5 Process Control Module PC4 Diagnostic LEDs 53 7 6 Diagnostic LEDs On Process Control Module P...

Страница 5: ...r when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage...

Страница 6: ...Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent weld...

Страница 7: ...panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels cover...

Страница 8: ...web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website ww...

Страница 9: ...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 condi tions suivante...

Страница 10: ...u laine 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...

Страница 11: ...lt rieur 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 com...

Страница 12: ...stan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences D L nergie lectromagn tique risque de provoquer d...

Страница 13: ...r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Ap...

Страница 14: ...OM 246 466 Page 10...

Страница 15: ...0 1A 27 6 0 1A 16 5 0 1A 15 7 0 1A 13 6 0 1A 10 9 0 1A 10 9 0 2 10 4 0 4 225 A 29 V DC 100 Duty Cycle 10 300 A In CC Mode 80 V In CC Mode 22 8 0 1A 20 6 0 1A 12 4 0 1A 11 8 0 1A 10 3 0 1A 8 6 0 1A 8 3...

Страница 16: ...s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating...

Страница 17: ...cting A Location loc_2 3 96 243 893 A Do not stack units Beware of tipping 1 Lifting Forks Use lifting forks to move unit Extend forks beyond opposite side of unit 2 Hand Cart Use cart or similar devi...

Страница 18: ...r Heat Shrink Tubing 3 Braided Shield Cut off shield at end of jacket 4 Inner Core 5 Center Conductor 6 Ring Terminal Tools Needed 1 2 6 1 4 in 2 in 3 59 ft 2 4 5 3 8 in 1 in 208 810 Front View 3 7 Co...

Страница 19: ...select proper cable size 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal Connect positive weld cable to Positive weld terminal and negative cable to Negative weld terminal 3 Weld Outp...

Страница 20: ...0 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0...

Страница 21: ...ource Do not coil excess cables Use cables that are the appropriate length for the application Whenever using long weld cables longer than 50 ft 15 m try to arrange positive and negative weld cables t...

Страница 22: ...rkpiece This arrangement is a bad setup due to sensing leads being directly in the current flow path of the welding arc Interaction between welding circuits will affect voltage drop in the workpiece T...

Страница 23: ...Voltage Sensing Lead 6 Wire Feeder 7 Workpiece This arrangement is a better setup for supporting separate voltage feedback to the welding power sources The most accurate voltage sensing may not be ac...

Страница 24: ...work CB2 is rated at 15 amperes and protects the wire feeder from overload If CB2 opens the wire feeder does not work Press button to reset breaker If breaker continue to open contact a Factory Author...

Страница 25: ...ct closure to F indicates coolant flow switch is closed and recirculating coolant system is operational F Circuit common H Not used J Not used K Not used L Not used M Not used Circuit common is same e...

Страница 26: ...to socket B completes contactor control circuit C 10 volts dc input from power source to wire feeder with respect to socket D D Remote volt control circuit common E 0 to 10 volts dc remote volt trim...

Страница 27: ...460 575 Input Amperes A At Rated Output 19 5 17 6 10 5 10 0 8 7 7 7 Max Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses 2 20 20 10 10 10 8 Normal Operating Fuses 3 30 25 15 15 15 10 Min...

Страница 28: ...r through current transducer and connect to welding power source grounding terminal first Then connect input conductors L1 L2 and L3 to welding power source line terminals Reinstall side panel onto we...

Страница 29: ...constant current ramps with constant voltage control of peaks and backgrounds Adaptive response is controlled by peak and minimum current levels Benefits are shorter arc lengths better puddle control...

Страница 30: ...LED indicates which setup mode is active Setup mode parameters are shown in Display Windows see Items 13 and 15 Process LED When this LED is lit turn the Adjust knob to select the desired weld process...

Страница 31: ...on menu when using a PDA with PipePro Program Management software PipeProMgr Command values are displayed prior to welding and actual values are displayed while welding unless a PDA with PipePro Progr...

Страница 32: ...eder control cable or optional extension cable Connect 72 pin connector to I O receptacle RC72 on rear of power source Connect 10 pin connector into receptacle RC8 on rear of power source 4 Negative W...

Страница 33: ...but does have a gas setting go to Step 6 3 Push Setup button again Use the Adjust knob to choose Wire Type INCO MCOR CrMo SS or STL 4 Push Setup button again Use the Adjust knob to choose Alloy Type f...

Страница 34: ...urce 3 Negative Weld Cable 4 Positive Weld Cable 5 Workpiece 6 14 Pin Plug On Remote Foot Control Cable Turn off welding power source before connecting to foot control 14 pin plug 7 Remote Foot Contro...

Страница 35: ...put Use the Adjust knob to set the desired amperage b If Remote control is selected connect a remote device using a remote cable adapter 300 248 to connect to an Interconnect Cable and then connect th...

Страница 36: ...t sense lead to work clamp and attach work clamp as close to arc as possible 3 Volt Sense Cable 4 Negative Weld Cable 5 Positive Weld Cable 6 Workpiece 7 14 Pin Plug On Remote Hand Control Cable Turn...

Страница 37: ...Adjust knob to choose type of Control CTRL PANL or CTRL REMT a If Panel control is selected press the Wire Feed Speed Amps display button for amperage output Use the Adjust knob to set the desired amp...

Страница 38: ...Isolation Control 042 871 Without HF Unit Ref 099 082 C Ref 098 115 B Tools Needed 13 16 in 1 Electrode 1 2 Electrode 2 3 A Terminal 4 B Terminal 5 C Terminal 1 E 2 E 1 C B A FROM POWER SOURCE S1 2 3...

Страница 39: ...71 Without HF Unit Ref 099 082 C Ref 098 115 B Tools Needed 13 16 in 1 Electrode 1 2 Electrode 2 3 A Terminal 4 Bus Bar 5 B Terminal 6 C Terminal E 2 E 1 C B A FROM POWER SOURCE S1 TIG WORK POLARITY R...

Страница 40: ...Argon 2 Oxygen OX2 81 Argon 18 Helium 1 CO2 TRIA 90 Helium 7 5 Argon 2 5 CO2 TRIH 0 045 1 2 98 Argon 2 CO2 C2 98 Argon 2 Oxygen OX2 81 Argon 18 Helium 1 CO2 TRIA 90 Helium 7 5 Argon 2 5 CO2 TRIH DPLX...

Страница 41: ...2 C10 85 Argon 15 CO2 C15 75 Argon 25 CO2 C25 100 CO2 CO2 0 045 1 2 90 Argon 10 CO2 C10 85 Argon 15 CO2 C15 75 Argon 25 CO2 C25 100 CO2 CO2 E80 0 035 0 9 85 Argon 15 CO2 C15 100 CO2 CO2 FCAW N A Gas Y...

Страница 42: ...ower up the front panel will display messages indicating the status of the unit The first message is PLS WAIT PLS WAIT is an abbreviation for network updating and means the internal control network is...

Страница 43: ...0 100 275 w 175 Nominal 2 5 7 0 w 4 4 Nominal 50 55 w 53 Nominal 25 CO2 045 1 1 100 200 w 150 Nominal 2 5 5 1 w 3 8 Nominal 47 53 w 50 Nominal 25 90 10 045 1 1 100 200 w 150 Nominal 2 5 5 1 w 3 8 Nomi...

Страница 44: ...00 200 w 175 Nominal 2 5 5 1 w 4 4 Nominal 50 55 w 53 Nominal 25 90 10 045 1 1 100 200 w 175 Nominal 2 5 5 1 w 4 4 Nominal 50 55 w 53 Nominal 25 85 15 Stainless Steel Process Wire Size in mm Wire Feed...

Страница 45: ...w 5 1 Nominal 53 57 w 55 Nominal 16 98 2 CO2 045 1 1 150 250 w 200 Nominal 3 8 6 4 w 5 1 Nominal 53 57 w 55 Nominal 25 98 2 Ox ProPulse Stainless Steel Welding In Position 035 0 9 120 300 w 175 Nomina...

Страница 46: ...flow of the weld puddle and the silicon acts as a de oxidizer 2 It is important to have proper joint preparation and fit up Use a bevel at the pipe joint of 35 37 5 degrees 70 75 degrees inclusive wi...

Страница 47: ...SMAW EXX18 Program 8 Lift TIG Press the Arc Control button to confirm the reset The reset message is displayed for 2 seconds while factory program settings are being reloaded During the reset mode the...

Страница 48: ...the display message appears in approximately 15 seconds Rotate Adjust knob to check the program revision level of each module as follows PCM Process Control Module X UIM User Interface Module X WFCM W...

Страница 49: ...lace To be done by Factory Authorized Service Agent Reference Every 3 Months l Unreadable Labels Weld Terminals l Damaged Gas Hose nl Weld Cables nl Cords nl Gun Cables Every 6 Months OR Drive Rolls I...

Страница 50: ...nd method Do not put both hands inside unit Keep one hand free D Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists in in...

Страница 51: ...which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health Safety Code Section 25249 5 et seq Battery posts terminals and related access...

Страница 52: ...the display windows indicate whether Volts Arc Adjust or Wire Speed can be changed turning the Adjust knob Depending on the defined weld process either volts MIG or arc adjust RMD Pro can be changed...

Страница 53: ...re Check for any frayed wires at ground end of volt sensing lead that may prevent a good connection S Be sure that volt sense lead shielding is not touching center conductor S Be sure that wire feeder...

Страница 54: ...e Agent PLS WAIT The uim communication error indicates user interface module PC7 lost data communications Press any button on front panel to clear error If condition persists contact nearest factory a...

Страница 55: ...n the PCM board is not functioning properly Press Jog Purge button to clear error Leave the unit powered up for five minutes and then turn on the con tactor to clear the fault NET WAIT The network wai...

Страница 56: ...C2 2 Voltmeter Measure the dc voltage across the bus terminal and bus terminal on PC2 as shown until voltage drops to near 0 zero volts Measure input capacitor voltage on both inverter assemblies befo...

Страница 57: ...Diagnostic LEDs 1 LED2 LED1 LED4 LED3 7 6 Diagnostic LEDs On Process Control Module PC4 LED Status Diagnosis 1 On Indicates 25 volts dc is present on process control module PC4 Off Indicates 25 volts...

Страница 58: ...p Switch S2 Dip switches are used to identify each circuit board on the internal network Dip switch settings are different for each circuit board For proper operation do not change dip settings from t...

Страница 59: ...ches are used to identify each circuit board on the internal network Dip switch settings are different for each circuit board For proper operation do not change dip settings from those shown 216 958 A...

Страница 60: ...nal On from robot for jog retract Off Input signal Off from robot for no jog retract 12 On Input signal On from robot for purge Off Input signal Off from robot for no purge 13 On Input signal On remot...

Страница 61: ...ent on automation interface module PC9 Off Indicates 15 volts dc is not present on automation interface module PC9 28 On Indicates 15 volts dc is present on automation interface module PC9 Off Indicat...

Страница 62: ...ircuit board has encountered a recoverable fault Wait or cycle power to clear fault Red The circuit board has encountered an unrecoverable fault 7 12 Troubleshooting Trouble Remedy No weld output comp...

Страница 63: ...OM 246 466 Page 59 Notes...

Страница 64: ...OM 246 466 Page 60 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram For Welding Power Source...

Страница 65: ...OM 246 466 Page 61 243 024 B...

Страница 66: ...466 Page 62 SECTION 9 PARTS LIST Hardware is common and not available unless listed Ref 249 011 A 4 Fig 9 3 5 Fig 9 2 6 Fig 9 4 14 Fig 9 5 1 2 3 7 8 9 10 11 12 13 16 15 16 17 7 18 Figure 9 1 Main Ass...

Страница 67: ...Module Supply V 15V 1 11 198951 Terminal Block 1 12 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 13 226550 Filter Assy Secondary 1 14 Fig 9 5 Front Panel Assembly 1 227855 Kit Connectors W Washer...

Страница 68: ...802 955 A 3 4 5 6 7 8 33 34 35 17 18 20 21 23 24 25 23 36 29 26 13 27 28 30 31 10 11 15 14 2 9 19 37 38 23 22 32 12 Hardware is common and not available unless listed 7 6 13 1 16 Figure 9 2 Windtunnel...

Страница 69: ...RT1 RT2 RT3 214015 Thermistor NTC 30K Ohm 25 Deg C 7 18in Lead 3 25 PC2 222661 Circuit Card Assy Power Interconnect 1 199107 Clip Wire Stdf 20 30 Bndl 156hole 031 078thk 1 199108 Clip Wire Stdf 30 40...

Страница 70: ...083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 4 6 PC4 Process Control Module PCM see Table 9 1 1 7 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 8 210491 Tray Mtg PC Card 1 9 223439 I...

Страница 71: ...t eye shld thd stem 500 13 X 1 500 1 8 210505 Nameplate Rear 1 9 201058 Connector Rect 72 Pin Assy 1 10 210483 Bracket lift eye 1 11 CB1 083432 Supplementary Protector Man Reset 1P 10A 250VAC Frict 1...

Страница 72: ...em 14 Quantity 1 S1 207456 Switch Assy Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg 1 2 207895 Insulator Switch Power 1 3 179851 Knob Pointer 1 670 Dia X 250 Id Push On W Spring 1 4 User Interface Module...

Страница 73: ...ram revision may not match the serial number of the PipePro 300 shown in Table 9 1 In order to provide the correct replacement board it is necessary to know the program revision for each of the boards...

Страница 74: ...Notes...

Страница 75: ...bles No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Cont...

Страница 76: ...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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