OM-203 860C

October 2002

Processes
Gas Metal Arc (MIG) Welding

Description

Arc Welding Power Source

Auto Deltaweld
452

Visit our website at

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 9001:2000 Quality Warranty and service information for your
System 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 2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
This product, when used 2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
for welding or cutting,
produces fumes or 2-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
gases which contain 2-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
chemicals known to the 2-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
State of California to 2-7. 115 VAC Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
cause birth defects and,
2-8. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
in some cases, cancer.
(California Health & 2-9. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Code Section 2-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
25249.5 et seq.) 2-11. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-13. Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-14. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-1. Upper Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-3. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 4 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-3. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-4. Short Circuit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-5. Front Panel Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-6. Weld Interface Board PC12 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-7. Diagnostic LED’s On Weld Interface Board PC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-8. Customer Interface Board PC14 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-9. Diagnostic LED’s On Customer Interface Board PC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-10. Motor Board PC13 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-11. Diagnostic LED’s On Motor Board PC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 6 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPTIONS AND ACCESSORIES
WARRANTY
 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
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.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
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
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conduc-
tor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
som _nd_7/02
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
to avoid the hazards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
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
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-203 860 Page 1
 ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
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).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
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.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 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
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-203 860 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
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.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-203 860 Page 3
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269–9101 (phone: 617–770–3000, website: www.nfpa.org and www.
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202–4102 (phone: 703–412–0900, web-
site: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-203 860 Page 4
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800–463–6727 or in Toronto 416–747–4044, website: www.csa–in-
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212–642–4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (phone:
617–770–3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices––phone for Region 5, Chicago, is
312–353–2220, website: www.osha.gov).
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
 SECTION 1 – CONSIGNES DE SÉCURITÉ – À LIRE AVANT
UTILISATION
1-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
1-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 1–4.
Lire et respecter toutes ces normes.
Y L’installation, l’utilisation, l’entretien et les réparations ne doi-
vent être confiés qu’à des personnes qualifiées.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi–automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi-
tifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D Ne pas se servir d’une source de courant alternatif dans les zones humi-
des, les endroits confinés ou là où on risque de tomber.
D Ne se servir d’une source de courant alternatif QUE si le procédé de souda-
ge l’exige.
D Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser-
vir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-
lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor-
mes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assu-
rer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre–vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est en-
dommagé – tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
som _nd_fre 7/02
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi-
lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les me-
sures à prendre pour éviter tout danger.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur–le–
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
D Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et dé-
charger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé–sécurité (FTSS) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dû-
ment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respira-
ble.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irri-
tants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien venti-
lé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dé-
gager des fumées toxiques lorsqu’on les soude.
OM-203 860 Page 5
 LES RAYONS DE L’ARC peuvent cau-
ser des brûlures oculaires et cuta-
nées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) suscep-
tibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour re-
garder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incen-
die ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauf-
fement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de mé-
tal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneuse-
ment avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-
mité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de sou-
dage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’in-
cendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
D En cas de non utilisation, enlever la baguette d’électrode du porte–
électrode ou couper le fil au raz du tube–contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peu-
vent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalli-
ques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-203 860 Page 6
LES ACCUMULATIONS DE GAZ peu-
vent causer des blessures ou même
la mort.
D Couper l’alimentation en gaz protecteur en cas de
non utilisation.
D Veiller toujours à bien ventiler les espaces confinés ou porter un respira-
teur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent cau-
ser des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimu-
lateurs cardiaques.
D Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
D Ils doivent consulter leur médecin avant de s’appro-
cher d’un lieu où on exécute des opérations de sou-
dage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES endommagées
peuvent exploser.
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte–bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
cuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bou-
teille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression – elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-
tion ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz compri-
mé, les équipements associés et les publications P–1 de la CGA,
mentionnées dans les normes de sécurité.
1-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLO-
SION
D Ne pas placer l’appareil sur une surface inflam-
mable, ni au–dessus ou à proximité d’elle.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique – s’assurer que l’alimen-
tation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’ap-
pareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté op-
posé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respec-
ter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir-
cuits imprimés.
D Mettre un bracelet antistatique AVANT de mani-
puler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent cau-
ser des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent cau-
ser des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en en-
gageant le fil de soudage.
LES ORGANES MOBILES peuvent
causer des blessures.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radio-
navigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interféren-
ces, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sour-
ces de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interféren-
ces éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compati-
ble au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de sou-
dage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre confor-
mément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires tel-
les que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à dis-
tance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’appro-
cher des opérations de soudage à l’arc, de gou-
geage ou de soudage par points.
OM-203 860 Page 7
1-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443–9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443–9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269–9101 (téléphone : (617) 770–3000, sites Web : www.nfpa.org et
www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P–1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202–4102 (téléphone : (703) 412–0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca-
nadian Standards Association, Standards Sales, 178 boulevard
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnéti-
ques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs élec-
tromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumula-
tion de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la re-
cherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-203 860 Page 8
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463–6727 ou à Toronto : (416) 747–4044, site Web : www.csa–interna-
tional.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036–8002 (téléphone : (212) 642–4900,
site Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (télé-
phone : (617) 770–3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux – Téléphone pour la Région 5, Chicago : (312)
353–2220, site Web : www.osha.gov).
Afin de réduire les champs électromagnétiques en milieu de travail, res-
pecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-
mandé de respecter les consignes ci-dessus.
 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

A
A 30 in (762 mm) Including lift eye

B 23 in (584 mm)

38 in (965 mm) Including strain

C
C relief
B

D 35 in (889 mm)

F
G E 1-1/4 in (32 mm)
H
4 Holes

F 21-1/8 in (537 mm)

G 1-1/8 in (29 mm)

H 7/16 in (11 mm) Dia

Weight

E Front 545 lb (247 kg)

800 453-A / 801 530

2-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.

OM-203 860 Page 11

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

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

OM-203 860 Page 12

 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 13

 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 14

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 15

 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 16

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

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

OM-203 860 Page 17

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 18

 SECTION 3 – OPERATION
3-1. Upper Front Panel Controls

8 9
1 2 3 4 5 6

1 Jog Forward Push Button
Advances wire out of the gun.
2 Wirefeed Indicator LED
LED lights when wire feed motor is
energized.
3 Jog Reverse Push Button
Retracts wire up into the gun.
4 Gas Indicator LED
LED lights when gas solenoid is energized.
5 Purge Push Button
Momentarily energizes gas solenoid to
purge air from gun shielding gas line, or to
adjust shielding gas regulator.
6 Contactor Indicator LED
LED lights when welding power source
contactor is energized.
7 Main Display
Shows system state, error messages, com-
mands at idle and actual feedback during
welding.
8 Motor Circuit Breaker
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 19

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 20

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 21

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
Corrupted program data has been detected
or loaded. The “X” value indicates the pro-
gram number.
May be caused by incompatible information
on the data card or bad memory.
2 Memory Range Error Display
Improper welding power source range is
selected. The “X” value indicates the pro-
gram number.
May be caused by improper range settings
or improper data loaded into the interface
unit.
3 No Volt Sensed Error Display
The arc voltage sense circuit did not receive
feedback within the required time after an arc
was established.
May be caused by an inability to establish an
arc in the pulse schedule, or a lack of voltage
feedback.
4 No Tach Sensed Error Display
The motor tachometer feedback is not
reaching the control.
May be caused by obstructions in the wire
feed system or a faulty wire drive system.
5 Arc Stop Error Display
Trouble is occurring at arc end.
May be caused by obstructions in the wire
feed system or a faulty wire drive system or
torch is touching part at end of weld.
6 Arc Start Error Display
Trouble is occurring at arc start.
May be caused by obstructions in the wire
feed system or a faulty wire drive system.
7 Stop Weld Cycle Error Display
An error has been detected and the robot
hasn’t stopped the weld cycle, causing the
interface unit to stop the weld cycle and wait
for the robot to stop.
8 No Flow Detected
No coolant is detected after preflow in the
weld cycle. Check coolant system and flow
switch for proper operation.
9 Ground Current Detect Error Display
Weld current has been detected in the earth
ground connection.
May be caused by a conductor making
connection to the unit chassis.
10 Wire Stick Error Display
The welding wire has stuck to the workpiece
at the end of the weld.
May be caused by poor weld conditions.
11 Arc Fail Time Out Error Display
An arc was not established within the allotted
time.
May be caused by an inoperable wire drive,
absence of shield gas, or improperly operat-
ing welding power source.
12 No Input IPM Display
Analog IPM (inches per minute) from robot is
not being received.
May be caused by having no wire feed speed
programmed at the robot.

OM-203 860 Page 22

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 23

 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 24

4-8. Customer Interface Board PC14 Diagnostic LED’s
1 Customer Interface Board PC14
Diagnostic LED’s are visible inside
unit, located on PC14 (see illustration
for board location).
Refer to Section 4-9 for information
on diagnostic LED’s.
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 25

 4-9. Diagnostic LED’s On Customer Interface Board PC14
LED Status Diagnosis

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 26

LED Status Diagnosis

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 27

4-10. Motor Board PC13 Diagnostic LED’s
1 Motor Board PC13
Diagnostic LED’s are visible inside
unit, located on PC13 (see illustration
1 for board location).
LED2 LED1
Refer to Section 4-11 for information
on diagnostic LED’s.
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 28

4-11. Diagnostic LED’s On Motor Board PC13
LED Status Diagnosis

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 29

 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 30

 SECTION 5 – ELECTRICAL DIAGRAM

. For Primary Circuit Diagram Portion, refer to Circuit Diagram

located inside wrapper of welding power source.

207 810-B

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-A

OM-203 860 Page 33

 Figure 5-3. Circuit Diagram For Control Board PC1 (Part 1 Of 2)
OM-203 860 Page 34
 208 198-1 (1 0f 2)

OM-203 860 Page 35

 208 198-2 (2 of 2)

Figure 5-4. Circuit Diagram For Control Board PC1 (Part 2 Of 2)

OM-203 860 Page 36
Notes

OM-203 860 Page 37

 Figure 5-5. Circuit Diagram For Microprocessor Board PC11
OM-203 860 Page 38
 191 838

OM-203 860 Page 39

 Figure 5-6. Circuit Diagram For Motor Board PC13
OM-203 860 Page 40
 209 749

OM-203 860 Page 41

 Figure 5-7. Circuit Diagram For Interface Board PC12 (Part 1 of 2)

OM-203 860 Page 42

 191 843-A (Part 1 of 2)

OM-203 860 Page 43

 Figure 5-8. Circuit Diagram For Interface Board PC12 (Part 2 of 2)

OM-203 860 Page 44

 191 843-A (Part 2 of 2)

OM-203 860 Page 45

 +35V

1
L2
R6 WBC
+22VDC 470
1W 5% MF
2 1

2
1

1
C14
1uF + + C16 D1 + C6
50V
22uF 1N4746A 470uF C64
35V 18V 50V 330pF
CER

1
100V
2

2
C12

2
.033uF
400V TP8

2
1
R69
+22VDC 22
R68
1

1
47

2
C9 C10
1

100pF + 5% 1/4W
1uF
SMT R4 50V C7
2 1 44.2K .1uF Z3
CER

1
TP5 TP4 1% 50V
2

2
HEATSINK1

1
C8 + C11
R5
U1 .1uF 1uF
2

22K
1 2 1 8 50V 50V
COMP VREF CER

1
SMT

2
2 7 R65
FB VCC
10 Q1
3 6 1 2 1 IRF640
I_SENSE OUTPUT .2 Ohms rds–on
1

TP1

3
4 5
RT/CT GND
1

D3 TP2
1

R3 UC3813D–5 \ UC 3845D PRLL5819

22K C5
SMT 330pF
100V TP3
2

R2
2

2 1
1

1K
1

1% + C4

1
C63 R66 1uF
330pF 100K 50V R1
100V 1% CER
2

0.06
NON–INDUCTIVE
MF
2

2 1W

Figure 5-9. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3)

OM-203 860 Page 46

 +20V_UNREG U3
LM340T–15
1 3
IN OUT RA+15V
T1 RA+15V RA–15V
XFRMR – MULTI–OUTPUT

GND
1

1
D4 L4 + C3
2 2 1 1 2 470uF C19 + R71 R72

1
50V 100uF 2.21K 2.21K

2
1

BYJ20J BEAD 50V C67

2
1.5A C65 .1uF

2
600V .1uF 50V

2
10 9
50V TP7 TP6
2

8
RAGND
1

1
1
1 C66 C18 LED2 LED1
1

1
3 D8 .1uF U2 100uF + YELLOW YELLOW
50V C2 50V C68 SMT SMT
2

2
1 2 1 2 +
.1uF

GND
7 470uF
BYJ20J L3 50V 50V

2
1.5A BEAD
2

2 3
600V IN OUT RA–15V RAGND RAGND
6 LM7915CT
–20V_UNREG
+24RD
D7 L5 F1
2 1 1 2 1 2
RD_GND
1

1
BYJ20J BEAD 1A

1
600V C33 + C73 C34 R89
1.5A 470uF .1uF 100uF + Z1 2.21K
1

50V 50V 50V FUSE CLIP

2
1

R74 Z2
2

2
2.21K R999 FUSE CLIP TP39
2

330 RD_GND

2
PRELOAD RD_GND
2

TL431 LED4
2

1
U4 YELLOW
SMT

1
4
+22VDC
RD_GND
3 2

PC817
1

C29
.01uF
2

TP30
1

R14
D2 R20 44.2K
1

162K 1%
1%
2

TP29
2

TL431AI
1
6

R10
4.99K
C26
2

2 1

220pF RD_GND
1kV

C15
2 1
RAGND

220pF
1kV

Pensar 86147 (Part 1 of 3)

OM-203 860 Page 47

 RA+15V RAGND
+15V

1
1
RA+15V
RC97 C77 +15V
C72
.1uF
50V
C23
.1uF
50V
.1uF TP40

2
50V

2
1
6 AGND AGND RAGND

4
2 +15V TP45 U13A U11 RA–15V
R94

8
7 221K LM358 R92 1 TIL–300 3 +
DGND 1% 100
3 1 2 3 + 1% 5 1

1
8 +5V 1 1 2 2 2 –
4 2 – C75 R79 U7A
9 3 .1uF 44.2K LM324A
AGND +15V 1%

11
50V

2
5 –15V 6

2
10 C80 4 RAGND RA–15V
.01uF R29 R27

1
100V 44.2K 44.2K
CON\2X5\MILLER 1% 1% AGND

2
R13 RN4

2
RA+15V 12.1K 100K–ADJ

2
1%
+5V VCC GND DGND 1 2 1 3
.1uF

2
AGND C42 50V 1 2
.1uF
+5V +15V –15V C25 50V
+5V
1

2
1

C53 + C40 + C41 +15V

C89 100uF 100uF +
50V 50V 100uF
50V
.1uF
50V TP41 AGND
2

R93 TP51 U12

8
221K U13B R91 1 TIL–300 10 +
GND GND AGND AGND 1% LM358 100
1 2 5 + 1% 5 8

1
7 1 2 2 9 –
6 – C28 R17 U7C
3 .1uF 44.2K LM324A
+15V 50V 1%

2
6

2
C79 4
.01uF RAGND
R30 R28

1
100V 44.2K 44.2K
1% 1% AGND
2 R19 RN3

2
RA+15V 12.1K 100K–ADJ

2
1%
1 2 1 3
.1uF

2
AGND C39 50V 1 2
.1uF
C32 50V

+15V
1

C83
.1uF
50V RA+15V
2

+15V AGND

1
C46 AGND
.1uF 50V C74
1

2 1 .1uF
50V

2
C86 C84
TP64 .1uF .1uF
+15V +15V 50V 50V RAGND
2

TP61
TP50 U14A AGND –15V RA+15V
4

U15A U14B LM324A U8A

8
LM358 R36 R32 R96 LM324A + 3 1 RAGND LM358
8

100K 100K 100 + 5 1 5 U9 + 3

1% 1% 1%
1

+ 3 1 2 1 2 1 2 7 – 2 C45 2 1
WFS_CMD 1 – 6 R39 .1uF 2
–
1

2 C50 C44 44.2K 50V 3

– .1uF .1uF 11 1% RA+15V
2

6
50V 50V
2

4
4
TIL–300
4

–15V RAGND
2

+15V
AGND AGND R31 C35
2

RN5 12.1K 2 1
AGND TP57 1% AGND
1 3
.1uF
1

100K–ADJ 50V

2 1

C48
.1uF
50V

C47
.1uF 50V
2 1

+15V TP65 TP49

TP58 U14C RA+15V

U15B U14D LM324A U8B
8

LM358 R37 R33 R97 TP48 LM324A + 10 1 RAGND LM358

8

100K 100K 100 + 12 8 5 U10 + 5

1% 1% 1%
1

+ 5 1 2 1 2 1 2 14 – 9 C43 2 7
TRI M_CMD 7 – 13 R35 .1uF 6
–
1

6 C51 C82 44.2K 50V 3

– .1uF .1uF 1% RA+15V
2

6
50V 50V
2

4
TIL–300
4

RAGND
2

+15V
AGND AGND R34 C37
2

RN6 12.1K 2 1
AGND 1% AGND
1 3
.1uF
1

100K–ADJ 50V

2 1

C49
.1uF
50V

Figure 5-10. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3)

OM-203 860 Page 48

 TP35
RA+15V
Q3 R70
MMBT4401L D12 100
1%
3 2 2 1 1 2

1
5 + RLS4148 C13 +
680uF

1
7
6 TP37 25V
–
U7B

2
1
LM324A
R83
TP28 1K RAGND
1%

2
TP15

RA+15V TP18
Q2 R67
MMBT4401L D5 100
1%
3 2 2 1 1 2

1
12 RLS4148 C1 +
+
680uF

1
14
13 TP19 25V
–
U7D

2
1

LM324A
R75
1K RAGND
1%
2

K1
6
4
8
RELAY DPDT (MDX24–02)
11
13 K1_COMMON
RD_GND 9
1 +24RD
16 2 1

D13
DL4001

2
LED3
GREEN
SMT
1

R12
TP21 10K
1%
1 2

TP23 C21
.1uF 50V
TP24 2 1

1 2 RA+15V RAGND
R15 D11 TP13
10K RLS4148 TP10
1%

1
1 2 C27
.001uF 100V R7 C69 C20
2 1 100K .1uF .1uF
1% 50V 50V
TP33

2
1 2
RAGND RA–15V
R21 U5C U5B RA–15V
TP34 221K 9 6 U5A R88
11

1%
– –
1 2 8 7 LF347D 100K
1%
+ 10 1 2 + 5 – 2 1 2
1

1
R25 C36 D10 + 3 1 2
44.2K .01uF LF347D RLS4148 LF347D
1%
1

100V R85
2

R11 100K
2

1 2 1 R18 2 RAGND C24 1%

100K .1uF
R87 RA+15V 1% 50V
5.11K
2

R23
44.2K RAGND 221K TP20 TP32
2

1%
1 1% 2
3

RAGND

RN1
100K–ADJ 2
U5D
TP11 – 13
14 RAGND
1

+ 12
RA+15V RAGND
LF347D RAGND
1

C71 C22 TP16 R9

.1uF .1uF 10K TP12
50V 50V 1%
2

1 2
TP25 C31
RAGND RA–15V 1 2 .1uF 50V
R8 D6 2 1
10K RLS4148
1% TP26 TP14
1 2 C30
.001uF 100V R16
2 1 100K
1%
TP38
RA–15V 1 2
RC93
1
11

TP36 R86 U6A U6B TP22 11

221K 2 6 R77 2
1%
– –
U6C 100K RAGND
1 2 1 7 1% RAGND 12
+ 3 1 2 + 5 – 9 1 2 3
1

RAGND
LF347D 8 RAGND 13
R26 C38 D9 + 10 1 2 RD_GND 4
44.2K RLS4148
4

1% .01uF LF347D 14
1

100V R81 RAGND

2

RA+15V 5
TP31 R78 100K
2

1 2 1 R84 2 LF347D C70 1% 15

RAGND 100K
1% .1uF 6
R24 5.11K 50V
2

R22 16
44.2K RAGND 221K
2

1% 7
1 1% 2 17
8
3

RAGND 18
9
RA–15V
RN2 19
100K–ADJ 2 10
RA+15V
20
RA+15V
RAGND CON\2X10\MILLER
1

R76
100K
1% U6D
TP17 R73
1

12 +
14 1 2
2

13 –
R80
100K 100K
1% 1%
1

LF347D
+ C17
1

TP27 .47uF
TP9 50V
Pensar 86147 (Part 2 of 3)
2

R82
100K RAGND
1%
1

RAGND

OM-203 860 Page 49

 LED25 TP135 U2 2
+5V
R6 3 RED SMT 1 2

1
1 2 2 1 R5 8 R5 5 R5 2 R5 1 R5 4 R5 7 R4 8 R4 6
+24RD

1
2.21K C9 9 3 4
1% A0 10K
.1uF 1 OC16 4 TP134 1%
TP136 50V 5 6
A0 1% 1% 1% 1% 1% 1% 1%

2
AIN0

2
2 3 A1
GND 9 8
A2
LED24 TP132 1 OC15 4 A1 TP131 A3
RED SMT 11 10
R121 A4
1 2 2 1 2 3 A5 13 12
+24RD GND

1
2.21K C9 8 A6
1% .1uF OC14 A2 TP128
1 4 A7 74HC1 4
50V
TP133 AIN1 GND

2
2 3 U1 8
+5V
1 2

1
LED23 1 OC13 4 A3 TP101
R120 RED TP129 R4 4 R4 3 R4 5 R4 7 R4 2 R4 0 R3 8 R4 1 3 4
1 2 SMT
2 1 2 3 10K
1

+24RD 2.21K C9 7 GND 1%

5 6
1% .1uF TP83 B0 1% 1% 1% 1% 1% 1% 1%

2
50V TP76 B1 9 8
TP130 AIN2 TP70 B2
2

TP66 B3 11 10
LED22 TP59 B4
R119 RED SMT TP124 TP53 B5 13 12
1 2 2 1 TP46 B6
1

+24RD 2.21K C9 6 TP42 B7 74HC1 4

1% .1uF
50V U1 6
TP126 AIN3 1 2
2

3 4

LED16 +5V +5V +5V 5 6

R116 RED SMT
1 2 2 1 TP120 1 OC12 4 A4 TP119 9 8

1
+24RD 2.21K
1

1% C9 5 C5 7 C5 2 C5 5 AB_SEL 11 10 !AB_SEL
2 3
TP122 .1uF GND .1uF .1uF .1uF
50V 50V 50V

2
AIN4 50V 1 OC11 4 A5 TP112 13 12
2

LED15 GND GND GND 74HC1 4

2 3
RED SMT TP113 GND
R113
1 2 2 1 1 OC10 4 A6 TP85
+24RD 2.21K
1

1% C9 4 GND
2 3
TP117 .1uF
AIN5 50V 1 OC9 4 A7 TP91
2

R109 LED14 TP103 2 3

2.21K RED SMT GND
1 1% 2 2 1
+24RD
1

TP107 C9 3
.1uF
AIN6 50V
2

R106 LED13 TP92

2.21K RED SMT

+24RD 1 2 2 1
1%
1

TP96 C9 2
.1uF
AIN7 50V
RC100
2

1
RD_GND BIN_SINK1
9
2 BIN_SINK4
10 BIN_SINK2
3
BIN_SINK3 RD_GND
11
4 BIN_SINK5
12 AIN4 TP84
5 BIN_SINK6 TP86 LED12
AIN5 RED SMT
13
6 +24RD 1 2 2 1
1

AIN6 RD_GN D R105 C9 1

14
7 BIN_SINK7 2.21K .1uF 1 OC8 4 B0
1% 50V
15
RD_GND BIN_SINK0
2

8 BIN_SINK0 2 3
GND
16
RD_GND LED11 OC7 B1
1 4
SMT RED TP77
CON\2X8\MILLER 1 2 2 1 2 3
+24RD GND
R102
1

2.21K C9 0 1 OC6 4 B2
RC110 1% .1uF
RD_GN D BIN_SINK1 TP79 50V
1 2 3
BIN_SRC1 GND
2

9
2 BIN_SRC4 LED10 1 OC5 4 B3
10 BIN_SRC2 R101 RED TP71
3 1 2 SMT
2 1 2 3
BIN_SRC3 RD_GN D +24RD 2.21K GND
11
1

BIN_SRC5 1% C8 8
4
12 AIN4 TP74 .1uF
BIN_SRC6 BIN_SINK2 50V
5
AIN5
2

13
6 LED9 TP67
AIN6 RD_GN D RED SMT
14 R100
7 BIN_SRC7 1 2 2 1
+24RD 2.21K OC4 B4
15 1 4
RD_GN D
1

BIN_SRC0 1% C8 7
8
16 TP68 .1uF 2 3
RD_GN D BIN_SINK3 50V GND
TP87 OC3 B5
2

1 4
CON\2X8\MILLER TP127 LED8 TP60
TP123 R9 9 RED SMT 2 3
TP121 GND
1 2 2 1
10K U1 9 +24RD 2.21K OC2 B6
1 4
1

BIN_SRC0 1 1% 2 R103 1 16 1% C8 5
I1 O1
BIN_SRC1 1 2 R118 2 15 TP63 .1uF 2 3
I2 O2 GND
BIN_SRC2 1 2 R115 3 14 BIN_SINK4 50V
I3 O3
BIN_SRC3 2 R114 OC1 B7
2

1 4 13 1 4
I4 O4
BIN_SRC4 1 2 R117 5 12 LED7 TP54
I5 O5 SMT
BIN_SRC5 1 2 R112 6 11 R9 8 RED 2 3
I6 O6 GND
BIN_SRC6 1 2 R110 7 10 1 2 2 1
I7 O7 +24RD
TP125 8 9 2.21K
1

TP118 GND V+ 1% TP56 C8 1

TP80 RD_GND ULN2003 .1uF
BIN_SINK5 50V
2

LED6
R9 5 RED SMT TP47
TP97 1 2 2 1
+24RD 2.21K
1

1% C7 8
R108 TP52 .1uF
3

12.1K BIN_SINK6 50V

BIN_SRC7 1% Q4
2

1 2 1
MMBT4401L LED5 TP43
1

R9 0 RED SMT
2

R107 1 2 2 1
2.21K +24RD 2.21K
1

1% 1% C7 6
.1uF
2

RD_GN D BIN_SINK7 TP44 50V

RD_GND
2

Figure 5-11. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3)

OM-203 860 Page 50

 TP111

TP106

TP102 U2 0 RC98
2 18 TRIM_CMD
TP95 A1 B1 1 11 ARC_DET
3 A2 B2 17 2 12
4 16 WLDR_RDY
TP100 A3 B3 3 13 SPARE
5 15
A4 B4 4 14 FLOW_ERR
6 14
TP94 A5 B5 5 15 STK_ERR
7 13
A6 B6 6 16 TOUCH_SENSOR
8 A7 B7 12 7 17
9 11
A8 B8 AB_SEL 8 18
!AB_SEL 9 19
19
TP90 G WFS_CMD 10 20
+5V 1 2 1
DIR
20 PIN AMP–LATCH
TP89 R111 10K TP116 74H C245
1%
TP82 TP110

TP73 +5V +5V

TP75 U1 7

1
2 18
TP78 A1 B1 C5 6 C5 4
3 17
A2 B2 .1uF .1uF
4 16
TP72 A3 B3 50V 50V

2
5 15
TP62 TP69 A4 B4
6 14
A5 B5 GND GND
7 13
A6 B6
8 12
A7 B7
9 11
A8 B8
TP55 R104 19
+5V 1 2 1
G RC94
DIR
4
10K RD_GN D
74H C245 1
1% RD_GN D
7
!AB_SEL AIN0 5
TP81 AIN1 2
C5 8 8
.001uF RD_GN D AIN3 6
100V AIN7 3
2 1 AIN2 9
RD_GN D +24RD

TP137 1 2 CON\3X3\MILLE R

1
LED26
GREEN R6 1 R6 2
+5V 2 1 2 1SMT 1 2.67M 6 10K
1% TP138
R6 0

2
5
150 R6 4

3
1K Q5
2 U2 3 4 1 1% 2 1 MMBT4401L K1_COMMON
4N 32
R122

2
1 2
10K
RD_GND
RC96
K5
6 NCA_SPARE 1
RELAY_COM 4 8
NOA_SPARE RD_GN D
8 2
7
11 NCB_SPARE 3
13 L1 +35V 6
9 NOB_SPARE 2 1 4
D1 5 1 WBC 5
TP93 +35V
1 2 16
R4 9 DL4001
392
2 1% 1 1 2 RELAY DPDT (MDX24–02) CON\2X4\MILLER

LED20 GREEN
TP88 SMT

K6
6 NCA_READY RC91
RELAY_COM 4
8 NOA_READY 1
+24RD
RD_GN D 8
11 NCB_READY RELAY_COM 2
13 9
9 NOB_READY NCA_SPARE 3
TP98 D1 4 1 NOA_SPARE 10
+35V NCB_SPARE
1 2 16 4
R5 0 COMM_SPARE 11
392 DL4001 NOA_READY 5
1% RELAY DPDT (MDX24–02) NOB_SPARE
2 1 1 2 12
LED21 NCA_READY 6
TP99 GREEN COM_READY 13
SMT NOB_READY 7
NCB_READY 14
K2
6 NCA_STUCK
RELAY_COM 4 CON\2X7\MILLE R
8 NOA_STUCK

11 NCB_STUCK
13
9 NOB_STUCK RC92
U2 1 1 NCA_STUCK 6
TOUCH_SENSOR +35V NOA_STUCK
1 16 1 2 16 1
SPARE I1 O1 COMM_STUCK
2 I2 O2 15 11
WLDR_RDY 3 14 R5 3 D1 8 DL4001 NOB_STUCK 7
STK_ERR I3 O3 392 RELAY DPDT (MDX24–02) COMM_FLOW
4 13 2 1 1 2 2
FLOW_ERR I4 O4 LED17 NCB_STUCK
5 12 12
ARC_DET I5 O5 1% GREEN NCB_FLOW
6 11 8
I6 O6 SMT NCA_FLOW
7 I7 O7 10 3
8 9 TP104 TP105 NOB_FLOW 13
GND V+ COMM_ARC 9
NCB_ARC 4
ULN2003 K3 NOA_FLOW 14
6 NCA_FLOW NCA_ARC 10
RELAY_COM 4 NOA_ARC 5
GND 8 NOA_FLOW NOB_ARC 15

11 NCB_FLOW
13 CON\3X5\MILLE R
9 NOB_FLOW
1
+35V
1 2 16

R5 6 D1 7 DL4001
392 RELAY DPDT (MDX24–02)
2 1% 1 1 2
LED18
TP109 GREEN
SMT
K4
TP108 6 NCA_ARC
RELAY_COM 4
8 NOA_ARC

11 NCB_ARC
13
9 NOB_ARC
1
+35V
1 2 16

R5 9 D1 6 DL4001
Pensar 86147 (Part 3 of 3)
392 RELAY DPDT (MDX24–02)
TP114 2 1% 1 1 2
LED19
TP115 GREEN
SMT

OM-203 860 Page 51

 174 578-B

Figure 5-12. Circuit Diagram For Touch Sensor Board PC18

OM-203 860 Page 52

 191 531

Figure 5-13. Circuit Diagram For Power Distribution Board PC20

OM-203 860 Page 53

 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-B

Figure 6-1. Main Assembly

OM-203 860 Page 54

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 6-1 Main Assembly

. . . 1 . . . . . . . . . . . . +179 432
. . . 2 . . . . . . . . . . . . . 179 431
. . . 3 . . . . . . . . . . . . . 164 699
. . . 4 . . . . . . . . . . . . . 162 816
. . . 5 . . . . . . . . . . . . . 162 820
. . . 6 . . . . . . . . . . . . . 162 830
. . . 7 . . . . . . . . . . . . . 177 279
. . . 8 . . . . . . . . . . . . . 604 536
. . . 9 . . . . . Z1 . . . . 166 364
. . . 10 . . . . HD1 . . . . 168 829
. . . 11 . . . . CR6 . . . . 160 966
. . . 12 . . . . . . . . . . . . . 173 605
. . . 13 . . . C21-23 . . 163 906
. . . 14 . . . . . T2 . . . . 159 042
. . . 14 . . . . . T2 . . . . 159 041
. . . 14 . . . . . T2 . . . . 159 043
. . . 15 . . . . TE1 . . . . 159 244
. . . 16 . . . . . . . . . . . . . 601 835
. . . 17 . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . . . . 601 835
. . . . . . . . . . . . . . . . . . . 038 618
. . . 18 . . . . . . . . . . . . . 159 034
. . . 19 . . . . . . . . . . . . . . Fig 6-5
. . . 20 . . . . . F1 . . . *156 065
. . . 21 . . . . . W . . . . . 160 793
. . . 23 . . . . . . . . . . . . . 134 464
. . . 24 . . . . . . . . . . . . . 163 359
. . . 25 . . . . . C1 . . . . 182 661
. . . . . . . . . . . . . . . . . . . 163 535
. . . . . . . . . . . R6 . . . . 140 002
. . . . . . . . . . . . . . . . . . . 162 817
. . . 26 . . . . . . . . . . . . . 182 660
. . . 27 . . . . . T1 . . . . 189 835
. . . 28 . . . . . . . . . . . . . 166 442
. . . 29 . . . . . . . . . . . . . 166 441
. . . 27 . . . . . T1 . . . . 189 836
. . . 28 . . . . . . . . . . . . . 172 309
. . . 29 . . . . . . . . . . . . . 172 308
. . . 27 . . . . . T1 . . . . 189 837
. . . 28 . . . . . . . . . . . . . 172 427
. . . 29 . . . . . . . . . . . . . 172 426
. . . . . . . . . TP1,2 . . . 175 405
. . . . . . . . . TP4,5 . . . 168 891
. . . . . . . . . PLG13 . . 189 873
. . . . . . . . . RC13 . . . 189 874
. . . . . . . . . PLG6 . . . 168 847
. . . . . . . . . . RC6 . . . . 168 845
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONTACTOR, def prp 25A 2P 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR, 50 and 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . . . . . . . . . . . . 1
. . TRANSFORMER, control 50VA 24V 200/230/460 (60Hz) . . . . . . . . . . . . . . 1
. . TRANSFORMER, control 50A 24V (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONTACTOR, def prp 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CAPACITOR, elctlt 16000uf 60VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . RESISTOR, WW fxd 10W 500 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . BUS BAR, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . . . . . . 1
. . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . . . . . . 1
. . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 380/400/440 (consisting of) . . . . . . . . . . . . . . . 1
. . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-203 860 Page 55

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 6-1 Main Assembly (Continued)

. . . 30 . . . . . . . . . . . . . 161 294
. . . 31 . . . . . . . . . . . . . . Fig 6-2
. . . 32 . . . . SR1 . . . . 192 672
. . . . . . . . . PLG14 . . 115 094
. . . . . . . . . PLG7 . . . 152 249
. . . . . . . . . . RC7 . . . . 168 846
. . . . . . . . . . . . . . . . . . . 010 467
. . . . . . . . . . . R7 . . . ♦114 808
. . . 33 . . . . . . . . . . . . . 204 069
. . . 34 . . . PC18 . . . 174 573
. . . 35 . . . PC12 . . . 191 841
. . . 36 . . . PC11 . . . 210 361
. . . 37 . . . . PC1 . . . . 208 197
. . . 38 . . . . CR3 . . . . 052 964
. . . 39 . . . . T11 . . . . 204 979
. . . 40 . . . . CR5 . . . . 006 393
. . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECTIFIER, SCR main (Fig 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RESISTOR, WW fxd 375W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ELECTRONICS BOX (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD ASSY, touch sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD ASSY, weld interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD ASSY, processor w/prom . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, control 200VA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 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 56

 . Hardware is common and not

7
6 7
available unless listed.

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 57

 Item Dia. Part
No. Mkgs. No. Description Quantity

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 . . . 203 665 .. CIRCUIT CARD ASSY, customer interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

OM-203 860 Page 58

. Hardware is common and not
available unless listed.
2 3

4
5

Figure 6-3. Rectifier, SCR Main SR1 802 351

Item Dia. Part

No. Mkgs. No. Description Quantity
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
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 59

 Item Dia. Part
No. Mkgs. No. Description Quantity

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
... 11 . . . . . . . . . . . . . . . 194 745 .. BLOCKING DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . . 010 467 .. CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3
. Hardware is common and not 4
available unless listed. 5

6
2
1

(Fig.6-5)11
7
12

10 9 Ref. 802 798 / 800 707-B

Figure 6-4. Panel, Rear w/Components

+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.

OM-203 860 Page 60

 802 686-A

Figure 6-5. Blocking Diode

Item Part
No. No. Description Quantity

Figure 6-5. Blocking Diode (Fig 6-4 Item 11)

... 1 ............... 200 355 .. Bracket, Mtg Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 ............... 191 248 .. Heat Sink, rectifier snowflake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 ............... 086 353 .. Diode, Rect 800A 300V R7S Hockey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 ............... 048 775 .. Bus Bar, Tab Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 ............... 166 667 .. Clamp, spring thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ............... 201 059 .. Clamp, thyristor rectifier 4.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 ............... 048 420 .. Capacitor, cer disc .01 uf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 168 894 .. Thermostat, Nc Open 125F Close 105F No Flangew/leads . . . . . . . . . . . 1
..................... 192 731 .. Thermostat, Nc Open 203F Close 173F No Flangew/leads . . . . . . . . . . . 1

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 61


Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY – Subject to the terms and 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 date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Maxstar 85, 140
* Spot Welders
* Load Banks
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
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.
miller_warr 6/02
 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 to:
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. 8/02