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OM-257 220B
2012−10
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 450 CC/CV
(400 Volt Model) CE
Visit our website at
www.MillerWelds.com
File: MULTIPROCESS
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 will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick 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 parts list will then help you to decide the
Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System
Standard.
exact part you may need to fix the problem.
Warranty and service information for your particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most hassle-free warranty in the business.
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 or individual specification 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.
Mil_Thank 2009−09
TABLE OF CONTENTS
Serial Number And Rating Label Location
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Output Terminals And Selecting Cable Sizes*
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
Typical Connection For Remote Control Feeder GMAW-P Process
Pulsed MIG Welding Mode - GMAW-P Process
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process
V-Sense Feeder Welding Mode - GMAW/FCAW Process
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Low Open Circuit Voltage (OCV) Welding Modes
SECTION 10 − MAINTENANCE & TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
XMT 450 CC/CV 400V W/AUX POWER (CE)
Stock Number
907525
Council Directives:
•
2006/95/EC Low Voltage
•
2004/108/EC Electromagnetic Compatibility
•
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
•
IEC 609741:2005 Arc welding equipment – Part 1: Welding power sources
•
IEC 6097410:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
•
EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields (0 Hz – 300Hz)
Signatory:
September 28, 2012
_____________________________________
___________________________________________
David A. Werba
MANAGER
,
PRODUCT DESIGN COMPLIANCE
Date of Declaration
257859B
7
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1.
Symbol Usage
.
Indicates special instructions.
DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
1-2.
Arc Welding Hazards
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.
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 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
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
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
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, ground, and operate 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 conductor first − double-check connections.
D
Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
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.
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
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.
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. Disconnect cable for process not in use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.
HOT PARTS can burn.
D
Do not touch hot parts bare handed.
D
Allow cooling period before working on equipment.
D
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-257 220 Page 1
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 local forced ventilation at the arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand 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 watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
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 an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks 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, glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or 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
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 Do not weld where flying sparks can strike flammable material.
D
Protect yourself and others from flying sparks and hot metal.
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 containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D
Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).
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, sparks, and fire hazards.
D
Do not use welder to thaw frozen pipes.
OM-257 220 Page 2
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.
D
After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
D
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT 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.
BUILDUP OF GAS can injure or kill.
D
Shut off compressed gas supply when not in use.
D
Always ventilate confined spaces or use approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
D
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating 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.
Compressed 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, mechanical shocks, physical damage, 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 compressed gas cylinders, regulators, hoses, and fittings 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
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D
Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (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 EQUIPMENT can injure.
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.
D
Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
D
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
BATTERY EXPLOSION can injure.
D
Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
MOVING PARTS can injure.
D
Keep away from moving parts such as fans.
D
Keep all doors, panels, covers, and guards closed and securely in place.
D
Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.
D
Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
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.
FLYING SPARKS can injure.
D
Wear a face shield to protect eyes and face.
D
Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
D
Sparks can cause fires — keep flammables away.
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 injure.
D
Keep away from moving parts.
D
Keep away from pinch points such as drive rolls.
WELDING WIRE can injure.
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.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local codes.
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 promptly correct any interference problem resulting from the installation.
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 electronic 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-257 220 Page 3
1-4.
California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
1-5.
Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
1-6.
EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1.
Keep cables close together by twisting or taping them, or using a cable cover.
2.
Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3.
Do not coil or drape cables around your body.
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (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,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
4.
Keep head and trunk as far away from the equipment in the welding circuit as possible.
5.
Connect work clamp to workpiece as close to the weld as possible.
6.
Do not work next to, sit or lean on the welding power source.
7.
Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-257 220 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
7 fre_som_2011−10
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.
2-1.
Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures personnelles.
2-2.
Dangers relatifs au soudage à l’arc
.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger.
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Sec-
tion 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.
Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans trous.
D
S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.
D
Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D
Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D
D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D
Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.
D
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer 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
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D
Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes.
D
Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D
Ne pas 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 provenant d’une autre machine.
D
Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D
S’assurer que tous les panneaux et couvercles sont correctement en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.
D
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.
OM-257 220 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.
D
Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent provoquer des brûlures.
D
Ne pas toucher à mains nues les parties chaudes.
D
Prévoir une période de refroidissement avant de travailler à l’équipement.
D
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
D
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D
Ne pas souder dans des endroits situés 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 irritants.
D
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses
D
Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D
Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.
D
Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.
D
Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
OM-257 220 Page 6
LE SOUDAGE peut provoquer un incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
D
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.
D
Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.
D
Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
D
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D
Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des blessures dans les yeux.
D
Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas de non utilisation.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.
D
Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut affecter l’ouïe.
D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, 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 circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
D
Utiliser seulement des bouteilles de gaz comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.
D
Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille.
D
Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D
Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D
Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
Ne pas installer l’appareil à proximité de produits inflammables.
D
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.
D
Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.
D
Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
D
Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur.
D
Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D
Réduire le courant ou le facteur de marche avant de poursuivre le soudage.
D
Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.
D
Porter un écran facial pour protéger le visage et les yeux.
D
Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D
Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les circuits imprimés.
D
Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.
D
Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
OM-257 220 Page 7
Les PIÈCES MOBILES peuvent causer des blessures.
D Ne pas s’approcher des organes mobiles.
D
Ne pas s’approcher des points de coincement tels que des rouleaux de commande.
LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de provoquer des interférences.
D
Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D
Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction.
D
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EXPLOSION DE LA BATTERIE peut provoquer des blessures.
D
Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent causer des blessures.
D
S’abstenir de toucher des organes mobiles tels que des ventilateurs.
D
Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
D
Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du manuel et dans chaque section.
D
N’utiliser que les pièces de rechange recommandées par le constructeur.
D
Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.
2-4.
Proposition californienne 65 Avertissements
D
Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.
D
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
D
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
D
Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC risque de provoquer des interférences.
D L’énergie électromagnétique risque de provoquer des interférences pour 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 compatible électromagnétiquement.
D
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
D
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
D
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
D
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles 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 équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation.
OM-257 220 Page 8
2-5.
Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
2-6.
Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Les CEM peuvent créer des interférences avec certains implants médicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: Limiter par exemple tout accès aux passants ou procéder à une évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
1.
Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.
2.
Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.
3.
Ne pas courber et ne pas entourer les câbles autour de votre corps.
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (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,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
4.
Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.
5.
Connecter la pince sur la pièce aussi près que possible de la soudure.
6.
Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.
7.
Ne pas souder tout en portant la source de soudage ou le dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-257 220 Page 9
OM-257 220 Page 10
SECTION 3 − DEFINITIONS
3-1.
Additional Safety Symbols And Definitions
.
Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
OM-257 220 Page 11
Do not weld on drums or any closed containers.
Do not remove or paint over (cover) the label.
Disconnect input plug or power before working on machine.
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Always wear long sleeves and button your collar when servicing unit.
After taking proper precautions as shown, connect power to unit.
Do not use one handle to lift or support unit.
?
?
V
A
Consult rating label for input power requirements.
Safe16 2012−05
Safe20 2012−05
Safe30 2012−05
Safe27 2012−05
Safe28 2012−05
Safe29 2012−05
Safe31 2012−05
Safe34 2012−05
Become trained and read the instructions before working on machine.
Connect Green Or Green/Yellow grounding conductor to ground terminal first.
Connect input conductors (L1, L2, L3) to line terminals.
Safe35 2012−05
Safe36 2012−05
OM-257 220 Page 12
Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
V
>5min
=< 60
°
3-2.
Miscellaneous Symbols And Definitions
A
Amperage Panel
Output
V
V
Circuit Breaker
Become trained and read the instructions before working on the machine or welding.
Safe40 2012−05
Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 5 minutes after power is turned off before working on unit, OR check input capacitor voltage, and be sure it is near 0 before touching any parts.
Safe43 2012−05
Always lift and support unit using both handles. Keep angle of lifting device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
Alternating
Current (AC)
Remote
V
Voltage
On
Off
Direct Current
(DC)
Gas Tungsten Arc
Welding
Positive
Negative
Inductance
Voltage Input
Protective Earth
(Ground)
I
U
0
Hz
1max
Constant Current
Arc Force
Rated No Load
Voltage (Average)
Hertz
Pulsed
Rated Maximum
Supply Current
U
1
IP
I
1eff
Constant Voltage
Shielded Metal Arc
Welding (SMAW)
Primary Voltage
Degree Of
Protection
Lift-Arc Trigger
Hold Operation
(GTAW)
Maximum Effective
Supply Current
U
2
I
2
Foot Control
Gas Metal Arc
Welding (GMAW)
Conventional
Load Voltage
Rated Welding
Current
Single Phase
Increase
Line Connection
Three Phase Static
Frequency Converter-
Transformer-
Rectifier
X
Duty Cycle
%
Percent
Three Phase
Lift-Arc Operation
(GTAW)
OM-257 220 Page 13
SECTION 4 − INTRODUCTION
4-1.
Specifications
Input
Power
Rated Welding
Output
Three
Phase
450 A @ 38 Volts DC, 100%
Duty Cycle
*While idling with fan on
Amperage
Range
Voltage
Range
15 − 600 10 − 38
Maximum
Open-
Circuit
Voltage DC
90
Amperes Input
At Rated Load
Output 50/60 Hz,
Three-Phase
380V
32.6
(0.42*)
400V
32.1
(0.47*)
KVA KW
380V 400V 380V 400V
21.5
(0.28*)
22.3
(0.32*)
19.1
(0.07*)
19.2
(0.07*)
4-2.
Environmental Specifications
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored,
but is not intended to be used outside during precipitation unless sheltered.
4-3.
Features And Benefits
LVC t Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input pow-
er fluctuation.
Wind Tunnel Technology t
circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments.
Fan-On-Demand t
cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through the machine.
Thermal Overload Protection automatically shuts down the unit, only when necessary to prevent damage to internal
components if the duty cycle is exceeded or air flow and cooling are restricted (see Section 4-5).
Auto Remote Sense enables the unit to automatically sense the connection of a remote control. Operation of the
remote control is dependent on the Mode Switch Setting (see Section 6-2).
Lift-Arc t TIG starts provide a contamination free weld without the use of high frequency in the Lift-Arc TIG Welding
Adaptive Hot Start t
for Stick increases the output amperage at the start of a weld, eliminating electrode sticking
in CC and Stick Welding Modes (see Sections 9-2 and 9-3).
4-4.
Arc Controls
DIG control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes in
CC and Stick Welding Modes (see Sections 9-2 and 9-3).
Inductance influences the arc stiffness, bead width and appearance, and puddle fluidity in MIG and V-Sense Feeder
Welding Modes (see Sections 8-2 and 8-6).
OM-257 220 Page 14
4-5.
Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.
NOTICE − Exceeding duty cycle can damage unit and void warranty.
100% Duty Cycle At 450 Amperes
Overheating
Continuous Welding
60% Duty Cycle At 580 Amperes
6 Minutes Welding
0
Minutes
15
4 Minutes Resting
A/V
OR
Reduce Duty Cycle duty1 4/95 − SA-181 560 / 250 541-A
OM-257 220 Page 15
40
20
80
60
0
0
4-6.
Volt-Ampere Curves
CC Mode
100
90
80
70
60
50
40
30
20
10
0
0
TIG
MIN
STICK
80A
TIG
REMOTE
TIG
SCRATCH
0%
25%
ARC CONTROL (DIG)
50%
75%
100%
100 200 300
AMPERAGE
CV MODE
100
400
STICK
MAX
500
TIG
MAX
600
Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown.
MAX
MIN
100 200 300 400
AMPERAGE
500 600 700
252 918-A / 252 919-A
OM-257 220 Page 16
SECTION 5 − INSTALLATION
5-1.
Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure information.
S
The EMF assessment on this equipment was conducted at 0.5 meter.
S
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 3,660,003 at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short−circuit power Ssc greater than or equal to 3,660,003.
ce-emc 1 2011-09
5-2.
Serial Number And Rating Label Location
The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
5-3.
Dimensions and Weight
F
G
D
E
B
C
A
Hole Layout Dimensions
8-11/16 in. (221 mm)
11-3/8 in. (289 mm)
15-3/4 in. (400 mm)
22-7/16 in. (570 mm)
2-3/4 in. (70 mm)
3-3/8 in. (86 mm) Dia.
1/4-20 UNC 2B Thread
D C
14.5 in.
(368 mm)
26.8 in.
(681 mm)
17.2 in.
(437 mm)
Weight
F
E
G
122 lb (55.3 kg) A
B
Ref. 252 018-A
OM-257 220 Page 17
5-4.
Selecting a Location
Movement 2
OR
1
Location
4
3
Tipping
!
Do not move or operate unit where it could tip.
18 in.
(460 mm)
1 Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side of unit.
2 Lifting Handles
Use handles to lift unit.
3 Hand Cart
Use cart or similar device to move unit.
4 Line Disconnect Device
Locate unit near correct input power supply.
!
Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC
Section 20.
18 in.
(460 mm)
Ref. ST-151 556 / 800 611 / Ref. 250 026-B
Notes
OM-257 220 Page 18
5-5.
Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to weld output terminals.
!
Do not use worn, damaged, undersized, or poorly spliced cables.
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Positive
(+)
Negative
(−)
Welding
Amperes
100
150
200
250
300
350
400
500
10 − 60%
Duty
Cycle
AWG (mm 2 )
4 (20)
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
2/0 (70)
60 − 100%
Duty
Cycle
AWG (mm 2 )
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95)
10 − 100% Duty Cycle
AWG (mm 2 )
4 (20)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
3 (30)
1 (50)
2 (35) 1 (50) 1/0 (60) 1/0 (60)
1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
2/0 (70) 3/0 (95) 4/0 (120)
2x2/0
(2x70)
2x2/0
(2x70)
3/0 (95)
4/0 (120)
4/0 (120)
2x2/0
(2x70)
4/0 (120)
2x2/0
(2x70)
2x2/0
(2x70)
2x3/0
(2x95)
2x2/0
(2x70)
2x3/0
(2x95)
2x3/0
(2x95)
2x4/0
(2x120)
2x3/0
(2x95)
2x3/0
(2x95)
2x4/0
(2x120)
3x3/0
(3x95)
2x3/0
(2x95)
2x4/0
(2x120)
2x4/0
(2x120)
3x3/0
(3x95)
600 3/0 (95) 4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
3x3/0
(3x95)
3x4/0
(3x120)
3x4/0
(3x120)
*
This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**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.
( ) = mm 2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-J 2011−07
OM-257 220 Page 19
5-6.
Connecting Weld Output Cables
1
4
Do not place anything between weld cable terminal and copper bar.
Tools Needed:
3/4 in. (19 mm)
2
3
!
Turn off power before connecting to weld output terminals.
!
Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.
1 Weld Output Terminal
2 Supplied Weld Output Terminal Nut
3 Weld Cable Terminal
4 Copper Bar
Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld
5-7.
Remote 14 Receptacle Information
B
A
K
C
L
D M
N
E
J
I
F
G
H
Ref. 252 018-A
24 VOLTS AC
REMOTE
CONTROL
A/V
AMPERAGE
VOLTAGE
GND
Incorrect Installation 803 778-B output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean.
M
F
H
G
K
Socket*
A
B
C
D
E
Socket Information
24 volts AC. Protected by supplementary protector CB2.
Contact closure to A completes 24 volts AC contactor control circuit.
Output to remote control; +10 volts DC in MIG mode. 0 to +10 volts DC in other modes.
Remote control circuit common.
0 to +10 volts DC input command signal from remote control.
CC/CV select 0 to +10 volts DC.
Current feedback; +1 volt DC per 100 amperes.
Voltage feedback; +1 volt DC per 10 arc volts.
Circuit common for 24 volt AC circuit.
Chassis common.
*The remaining sockets are not used.
OM-257 220 Page 20
5-8.
115 Volts AC Duplex Receptacle And Supplementary Protectors
1
2 3
1 115 V 7 Amp AC Receptacle
2 Supplementary Protector CB1
3 Supplementary Protector CB2
CB1 protects duplex receptacle.
CB2 protects 24 volts AC portion of
Remote 14 receptacle from overload.
Press button to reset supplementary protector.
Ref. 257 348-A
Notes
OM-257 220 Page 21
5-9. Optional Gas Valve Operation And Shielding Gas Connection
4
GAS IN
3
5
1
2
Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve.
1 Cylinder
2 Regulator/Flowmeter
Install so face is vertical.
3 Gas Hose Connection
Fitting has 5/8-18 right-hand threads. Obtain and install gas hose.
4 Gas In Fitting
5 Gas Out Fitting
The Gas In and Gas Out fittings have 5/8-18 right-hand threads.
Obtain proper size, type, and length hose and make connections as follows:
Connect hose from shielding gas supply regulator/flowmeter to Gas
In fitting.
Connect hose coupler to torch.
Connect one end of gas hose to hose coupler. Connect remaining end of gas hose to Gas Out fitting.
Operation
The gas solenoid controls gas flow during the TIG process as follows:
Remote TIG
Gas flow starts with remote contactor on.
Gas flow stops at end of post−flow if current was detected, or with remote contactor off if no current was detected.
Lift−Arc TIG
Gas flow starts when tungsten touches work (touch sensed).
Gas flow stops at end of post−flow.
Scratch Start TIG
Gas flow starts when current is detected.
Gas flow stops at end of post−flow.
Post−flow time is factory set to 4 seconds per 100 amps of weld current. The minimum post−flow time is 5 seconds. The maximum post− flow is 24 seconds (post flow settings are not adjustable by the end user).
GAS OUT
Ref. 252 021-A / 257 348-A
OM-257 220 Page 22
5-10. Electrical Service Guide
Elec Serv 2011−08
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency
(+
10%) and voltage
(+
10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Three Phase
380
32.6
400
32.1
Input Voltage (V)
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
Normal Operating Fuses 3
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
40
50
8
279
(85)
10
35
45
8
309
(94)
10
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5”. See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Notes
OM-257 220 Page 23
5-11. Connecting Input Power
9
3
4
10
1
= GND/PE Earth Ground
11
8
L1
L2
L3
7
3
4
2
1
Tools Needed:
5/16 in.
OM-257 220 Page 24
L1
L2
L3
7
6
5
Input 2012−05 / Ref. 803 766-A / 257 348-A
5-11. Connecting Input Power (Continued)
!
Turn Off welding power source, and check voltage on input capacitors
according to Section 10-3 before
proceeding.
!
Installation must meet all National and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/ tagout devices.
!
Make input power connections to the welding power source first.
!
Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.
See rating label on unit and check input voltage available at site.
1 Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 5-5. Conductors must comply with
national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.
Welding Power Source Input Power
Connections
2 Strain Relief
Route conductors (cord) through strain relief and tighten screws.
3 Welding Power Source Grounding
Terminal
4 Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding conductor to machine grounding terminal first.
5 Input Filter Board
6 Welding Power Source Line Terminals
7 Input Conductors L1, L2, L3
Connect input conductors L1, L2, and L3 to welding power source line terminals.
Reinstall side panel on welding power source.
Disconnect Device Input Power
Connections
8 Disconnect Device (switch shown in the OFF position)
9 Disconnect Device Grounding Terminal
10 Disconnect Device Line Terminals
Connect green or green/yellow grounding conductor to disconnect device grounding terminal first.
Connect input conductors L1, L2, and L3 to disconnect device line terminals.
11 Over-Current Protection
Select type and size of over-current protec-
tion using Section 5-10 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures to put unit in service.
Input5 2012−05
Notes
Work like a Pro!
Pros weld and cut safely. Read the safety rules at the beginning of this manual.
OM-257 220 Page 25
SECTION 6 − GENERAL OPERATION
6-1.
Front Panel
2 3 4
1
8
10 9
252 022-A / 256 366-A
.
Weld process operation sections describe functionality of the identified items.
1 Remote 14 Receptacle
2 Left Display
3 Right Display
.
The meters display the actual weld output values after arc initiation and remains displayed for approximately three seconds after the arc is broken.
4 Adjust Control
5 Power Switch
6 Arc Control
7 Optional Gas Valve Knockout
8 Mode Switch
9 Weld Output Terminal (−)
10 Weld Output Terminal (+)
OM-257 220 Page 26
5
6
7
6-2.
Mode Switch Settings
Switch Position Process
Scratch Start TIG GTAW
Lift-Arc TIG
Scratch Start TIG
MIG
Pulsed MIG
Stick
Stick
V-Sense Feeder
*Requires an external pulsing device.
GTAW
GTAW
GMAW
GMAW-P*
SMAW
CAC-A
SMAW
CAC-A
GMAW
Notes
Output Control
Electrode Hot
Remote 14
Remote 14
Remote 14
Remote 14
Remote 14
Electrode Hot
Electrode Hot
Panel Adjust
Amps
Amps
Amps
Volts
N/A
Amps
Amps
Volts
Remote Adjust
% Panel Amps
% Panel Amps
% Panel Amps
Volts
Arc Length (0−100)
% Panel Amps
% Panel Amps
Volts
OM-257 220 Page 27
SECTION 7 − GTAW OPERATION
7-1.
Typical Connection For GTAW Process
2
3
4
5
!
Turn off power before making connections.
1 Foot Control
2 Positive (+) Weld Output
Terminal
3 Remote 14 Receptacle
Connect desired remote control to
Remote 14 receptacle if required.
4 Gas In Connection (Optional)
5 Gas Cylinder
6 Gas Out Connection
(Optional)
7 Negative (−) Weld Output
Terminal
8 TIG Torch
9 Workpiece
1
7
6
9
8
Ref. 252 920-A
OM-257 220 Page 28
7-2.
Scratch Start TIG Welding Mode - GTAW Process
2
84.5 85
3 4
1
!
Weld terminals are energized at all times in Scratch Start TIG welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
Setup
For typical system connections refer to
Rotate Mode Switch to SCRATCH START
TIG position as shown.
The open circuit voltage is shown in the Left
Display. Preset amperage is shown in the
Right Display.
256 366-A
Operation
The Adjust Control is used to set desired preset amperage.
.
If a remote control is used for amperage adjustment, the adjustment will function as a percentage of the preset amperage.
.
For best results, gently scratch the tungsten electrode to the work to initiate an arc. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc.
OM-257 220 Page 29
7-3.
Lift-Arc TIG Welding Mode - GTAW Process
2 3
85
4
1
256 366-A
6
“Touch”
1 − 2
Seconds
5
!
Weld terminals are energized through the remote control in TIG welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
5 Workpiece
6 Tungsten Electrode
Setup
For typical system connections refer to
Rotate Mode Switch to LIFT-ARC TIG position as shown.
Preset amperage is shown in the Right Dis-
OM-257 220 Page 30 play.
Normal open-circuit voltage is not present before the electrode touches the workpiece, instead a low sensing voltage is present. The sensing voltage allows the electrode to touch the workpiece without overheating, sticking, or getting contaminated.
Operation
The Adjust Control is used to set desired preset amperage.
A remote control is required to turn on the weld output.
To start welding, momentarily depress output switch. Touch tungsten electrode to workpiece at weld start point. Slowly lift
Do NOT Strike Like A Match!
electrode. An arc will form when electrode is lifted. If welding arc is not established within 3 seconds, output will turn off. To stop welding, momentarily depress output switch and output will shut off.
.
If a remote control is used for amperage adjustment, the adjustment will function as a percentage of the preset amperage.
.
For best results, firmly touch the tungsten electrode to the workpiece at the weld start point. Hold electrode to workpiece for 1-2 seconds, and lift electrode. An arc will form when the electrode is lifted. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc.
7-4.
Remote Scratch Start TIG Welding Mode - GTAW Process
2 3 4
85
1
!
Weld terminals are energized through the remote control in TIG welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
Setup
For typical system connections refer to
Rotate Mode Switch to TIG position as shown.
The preset amperage is shown in the Right
Display.
256 366-A
Operation
The Adjust Control is used to set desired preset amperage.
A remote control is required to turn on the weld output.
.
If the remote control has an amperage adjustment, the adjustment will function as a percentage of the preset amperage.
.
For best results, gently scratch the tungsten electrode to the work to initiate an arc. To minimize arc flare at the end of the weld, pull back the electrode quickly to extinguish the arc.
OM-257 220 Page 31
SECTION 8 − GMAW/FCAW OPERATION
8-1.
Typical Connection For Remote Control Feeder GMAW/FCAW Process
9
1
2
3
4
5
6
7
8
!
Turn off power before making connections.
1 Remote 14-Receptacle
2 Positive (+) Weld Output Terminal
3 Negative (−) Weld Output Terminal
4 Ground Cable to Workpiece
5 Workpiece
6 Gun
7 Wire Feeder
8 Gas Hose
9 Gas Cylinder
Ref. 252 921-A
Use of shielding gas is dependant on Wire
Type.
.
The connection diagram illustrates
DCEP (reverse polarity) suitable for all wires except self-shielded FCAW. The majority of self-shielded FCAW wires require DCEN (straight polarity).
OM-257 220 Page 32
8-2.
MIG Welding Mode - GMAW/FCAW Process
2
2 5.0
3 4
1
!
Weld terminals are energized through the remote control in MIG welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
Setup
For typical system connections refer to
Rotate Mode Switch to MIG position as shown.
The preset voltage is shown in the Left Display.
Operation
The Adjust Control is used to set desired preset voltage.
.
The preset voltage can be adjusted remotely at the wire feeder if the feeder has a voltage control. This voltage control will override the Adjust Control of
256 366-A preset voltage on the welding power source.
Arc Control (Inductance)
Rotate Arc Control to select desired inductance setting from 0 to 100. Use lower inductance settings to stiffen the arc and reduce puddle fluidity. Use higher inductance settings to soften the arc and increase puddle fluidity.
.
For self-shielding wires (FCAW), adjust Arc Control to FCAW setting.
OM-257 220 Page 33
8-3.
Typical Connection For Remote Control Feeder GMAW-P Process
1
10
2
3
4
9
8
5
6
7
!
Turn off power before making connections.
1 Optima - External Pulsing Device
2 Remote 14-Receptacle
3 Positive (+) Weld Output Terminal
4 Negative (−) Weld Output Terminal
5 Ground Cable to Workpiece
6 Workpiece
7 Gun
8 Wire Feeder
9 Gas Hose
10 Gas Cylinder
Use of shielding gas is dependant on Wire
Ref. 252 836-A
Type.
.
The connection diagram illustrates
DCEP (reverse polarity) suitable for all wires except self-shielded FCAW. The majority of self-shielded FCAW wires require DCEN (straight polarity). Flux cored wires are not pulsed. No pulse program available for FCAW.
OM-257 220 Page 34
8-4.
Pulsed MIG Welding Mode - GMAW-P Process
2
PP.P PPP
3 4
1
!
Weld terminals are energized through the remote control in
Pulsed MIG welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
Setup
For typical system connections refer to
Rotate Mode Switch to PULSED MIG position as shown.
Left and Right Display will show PPP PPP.
256 366-A
Operation
This unit requires an external pulsing device, like an Optima to pulse MIG weld.
See Optima owner’s manual for more information.
.
When Pulsed MIG mode is selected,
Arc Control is not functional.
OM-257 220 Page 35
8-5.
Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process
1
2
9
8
10
!
Turn off power before making connections.
1 Positive (+) Weld Output
Terminal
2 Negative (−) Weld Output
Terminal
3 Ground Cable to Workpiece
4 Workpiece
5 Voltage Sensing Clamp
6 Gun
7 Gun Trigger Receptacle
8 Wire Feeder
9 Gas Hose
10 Gas Cylinder
Use of shielding gas is dependant on Wire Type.
.
The connection diagram illustrates DCEP (reverse polarity) suitable for all wires except self-shielded FCAW. The majority of self-shielded FCAW wires require DCEN (straight polarity).
3
4
7
5
6
Ref. 252 924-A
OM-257 220 Page 36
8-6.
V-Sense Feeder Welding Mode - GMAW/FCAW Process
2
2 5.0
3 4
1
256 366-A
!
Weld terminals are energized at all times in V-Sense Feeder welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
Setup
For typical system setup connections refer
Rotate Mode Switch to V-SENSE FEEDER position as shown.
The Left Display toggles between open circuit voltage and preset voltage.
Operation
The Adjust Control is used to set desired preset voltage.
.
The Left Display toggling momentarily pauses while the preset voltage is adjusted.
Arc Control (Inductance)
Rotate Arc Control to select desired inductance setting from 0 to 100. Use lower inductance settings to stiffen the arc and reduce puddle fluidity. Use higher inductance settings to soften the arc and increase puddle fluidity.
.
For self-shielding wires (FCAW), adjust Arc Control to FCAW setting.
OM-257 220 Page 37
SECTION 9 − SMAW/CAC-A OPERATION
9-1.
Typical Connection For SMAW And CAC-A Process
3
4
5
!
Turn off power before making connections.
1 Electrode Holder
(Carbon Arc)
For CAC-A process connect carbon arc cutting torch to to positive weld output terminal.
2 Electrode Holder
3 Positive (+) Weld Output
Terminal
4 Remote 14 Receptacle
Connect desired remote control to remote 14 receptacle as required.
5 Compressed Air LIne
6 Negative (−) Weld Output
Terminal
7 Workpiece
1
2
6
7
Ref. 252 926-A
OM-257 220 Page 38
9-2.
Remote Stick Welding Mode - SMAW/CAC-A Process
2 3
85
1
256 366-A
!
Weld terminals are energized through the remote control in Remote Stick welding mode.
1 Mode Switch
2 Right Display
3 Adjust Control
Setup
For typical system connections refer to
Rotate Mode Switch to Remote Stick position as shown.
The preset amperage is shown in the Right
Display with the Amps Indicator lit.
Operation
The Adjust Control is used to set desired preset amperage.
A remote control is required to turn on the weld output.
.
If the remote control has an amperage adjustment, the adjustment will function as a percentage of the preset amperage.
Adaptive Hot Start automatically increases welding amperage at the start of a weld.
This helps eliminate electrode sticking during arc initiation.
.
For best results at the end of the weld, pull back the electrode quickly to extinguish the arc.
Arc Control (Dig)
Rotate Arc Control to select desired dig setting from 0 to 100.
Dig control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes. Lower the dig setting for smooth running electrodes like
E7018 and increase the dig setting for stiffer, more penetrating electrodes like E6010.
.
Use this mode for Air Carbon Arc
(CAC−A) cutting and gouging. For best results, adjust Arc Control to maximum.
OM-257 220 Page 39
9-3.
Stick Welding Mode - SMAW/CAC-A Process
2
84.5 85
3 4
1
!
Weld terminals are energized at all times in Stick welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
Setup
For typical system connections refer to
Rotate Mode Switch to STICK position as shown.
The open circuit voltage is shown in the Left
Display and the preset amperage is shown in the Right Display.
Operation
The Adjust Control is used to set desired preset amperage.
Adaptive Hot Start automatically increases welding amperage at the start of a weld.
This helps eliminate electrode sticking during arc initiation.
.
For best results at the end of the weld, pull back the electrode quickly to extinguish the arc.
256 366-A
Arc Control (Dig)
Rotate Arc Control to select desired dig setting from 0 to 100.
Dig control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes. Lower the dig setting for smooth running electrodes like
E7018 and increase the dig setting for stiffer, more penetrating electrodes like E6010.
.
Use this mode for Air Carbon Arc
(CAC−A) cutting and gouging. For best results, adjust Arc Control to maximum.
OM-257 220 Page 40
9-4.
Optional Low Open Circuit Voltage (OCV) Welding Modes
Low OCV Operation
The unit can be optionally configured for low open circuit voltage
(OCV) operation in Stick and
Scratch Start TIG modes. When the unit is configured for low OCV operation only a low sensing voltage
(approximately 15 VDC) is present between the electrode and the workpiece prior to the electrode touching the workpiece. Consult a
Factory Authorized Service Agent for information regarding how to configure unit for low OCV welding operation.
Notes
OM-257 220 Page 41
SECTION 10 − MAINTENANCE & TROUBLESHOOTING
10-1. Routine Maintenance
Replace
Damaged Or
Unreadable
Labels
!
Disconnect power before maintaining.
3 Months
Repair Or
Replace
Cracked
Cables
.
Maintain more often during severe conditions.
Replace Cracked
Torch Body
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
Blow Out Inside
10-2. Blowing Out Inside Of Unit
!
Do not remove case when blowing out inside of unit.
To blow out unit, direct airflow through front and back louvers as shown.
Ref. 252 018-A
OM-257 220 Page 42
10-3. Removing Case and Measuring Input Capacitor Voltage In 400 VAC Models
1
4
Typical Bleeder Resistor
25 to 1000 ohm,
5 watt resistor
#16 AWG 1000 volts DC insulation rating, approx.
3 in. (76 mm) leads
!
Turn Off welding power source, and disconnect input power.
!
Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.
1 Right Side Panel
To remove panel, remove screws securing panel to unit.
2 Interconnect Board PC2
3 Voltmeter
Measure the DC voltage across the screw terminals on PC2 as shown until voltage drops to near 0 (zero) volts.
.
If the capacitor voltage does not drop to near zero after several minutes, use a bleeder resistor of between 25 and 1000 ohms, at least 5 watts, #16
AWG 1000 volts DC insulating rating wire to discharge the capacitor(s) .
4 Typical Bleeder Resistor
An example of a typical bleeder resistor is shown on this page.
Proceed with job inside unit. Reinstall right side panel when finished.
2
400 VAC input:
+ lead to lower terminal, − lead to upper terminal
256 682-A
OM-257 220 Page 43
10-4. Help Displays
P-5
P-6
P-8
P25
P-1
P-2
P-3
HE.L
HE.L
HE.L
HE.L
HE.L
HE.L
HE.L
.
All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.
Help 1 Display
Indicates a malfunction in the primary power circuit. If this display is shown, contact a Factory Authorized Service Agent.
Help 2 Display
Indicates a malfunction in the thermal protection circuitry. If this display is shown, contact a Factory Authorized Service Agent.
Help 3 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-5). Operation will
continue when the unit has cooled.
Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-5). Operation will
continue when the unit has cooled.
Help 6 Display
Indicates a malfunction in the input circuitry of the unit. If this display is shown, contact a
Factory Authorized Service Agent.
Help 8 Display
Indicates a malfunction in the secondary power circuit of the unit. If this display is shown, contact a Factory Authorized Service
Agent.
Help 25 Display
Indicates machine has reached Duty Cycle
limit (See Section 4-5). Unit must be left on to
power the fan for cooling. Duty Cycle limit will automatically reset when unit has cooled.
OM-257 220 Page 44
10-5. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-11).
No weld output; meter display On.
Erratic or improper weld output.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11).
Check for proper input power connections (see Section 5-11).
Input voltage outside acceptable range of variation (see Section 5-10).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-5).
Use proper size and type of weld cable (see Section 5-5).
Clean and tighten all weld connections.
Check for correct polarity.
Reset supplementary protector CB1 (see Section 5-8).
No 115 volts AC output at duplex receptacle.
No 24 volts AC output at Remote 14 receptacle.
Reset supplementary protector CB2 (see Section 5-8).
Notes
OM-257 220 Page 45
SECTION 11 − ELECTRICAL DIAGRAM
OM-257 220 Page 46
Figure 11-1. Circuit Diagram
256 909-A
OM-257 220 Page 47
5
4
6
7
SECTION 12 − PARTS LIST
14
13
15
12
16
.
Hardware is common and not available unless listed.
17
9
19
10
11
8
18
20
21
22
23
24
3
1
2
43 42
47
48
46
45
44
41
35
37
36
39
38
40
29
31
34
32
30
33
Figure 12-1. Parts Assembly
OM-257 220 Page 48
25
26
27
28
56
49
50
51
54
57
55
59
60
61
62
66
58
65
63
52
53
67
68
69
70
64 72
71
93
92
73
91
90
74
75
76
89
88
87
86
85
77
59
78
79
80 81
82
83
84
257 223-A
OM-257 220 Page 49
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 12-1. Parts Assembly
Quantity
. . .
1 . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . .
2 . . . . . . . . . . . . .
. . .
3 . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . .
4 . . . . . . . . . . . . .
. . .
5 . . . . . . . . . . . . .
. . .
6 . . . . . . . . . . . . .
255 082
175 256
. .
. . . .
Panel, Side Rh W/Nut Insert (Includes)
Insulator, Side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
179 310
255 081
. . . .
. .
Label, General Precautionary Wordless Intl Small
Panel, Side Lh W/Nut Insert (Includes)
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
178 551
+249 111
. . . .
. .
Insulator, Side
Cover, Top
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135 483
249 848
. .
. .
Label, Important Remove These Two Handle Screws
Handle, Rubberized Carrying
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
7 . . . . . . . . . . . . .
. . .
8 . . . .
HD1 . . .
179 309 . .
Label, Warning Falling Equipment Can Injure-Wordle
168 829 . .
Transducer, Current 1000A Module Max Open Loop s . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
. . . . . . . . . . .
. . . . . . . .
L5 . . . .
PLG 9, 19 . .
254 680
115 094
. .
. .
Cable Assy, Current Feedback W/Ferrite Core
Housing Plug+Pins (Service Kit)
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
9 . . . . . . . . . . . . .
183 827 . .
Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
. . .
. . .
. . .
10
11
12
13
14
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . .
PC7 . . .
154 408
196 355
. .
. .
Bushing, Snap−In Nyl .562 Id X .875 Mtg Hole Cent
Insulator, Screw
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
179 276
252 239
. .
. .
Bushing, Snap−In Nyl 1.000 Id X 1.375 Mtg Hole Cent
Bracket, Mtg Filter Board Lower
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
231 563 . .
Circuit Card Assy, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
15 . . . . . . . . . . . . .
. . .
16 . . . . . . . . . . . . .
. . .
17 . . . . . . . . . . . .
252 237
145 743
. .
. .
Bracket, Mtg Filter Board Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lug, Univ W/Scr 600V 2−14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . .
+249 527 . .
Windtunnel, Lh W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
18 . . . . . . . . . . . . .
. . .
19 . . . . . . . . . . . . .
219 844 . .
Label, Warning Electric Shock/Exploding Parts-Wdle
249 618 . .
Insulator, Heat Sink s . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
. . .
. . .
20
21
22
23
. . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . .
RT1 . . .
. . . . . . . . . . . . .
199 798
201 531
. .
. .
Thermistor, NTC 30K OHM @ 25 Deg C 18.00In 2500V
Kit, Diode Power Module
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
199 840
232 296
. .
. .
Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor/Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C21−C24 .
180 877 . .
Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
. . .
24
25
26
. . . . . . . . . . . . .
. . . . .
T1 . . . .
. . . . . . . . . . . . . .
204 165
255 992
. .
. .
Heat Sink, Rect Dual Diode
XFMR, HF 400V
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
249 110 . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
27
28
. . . . . . . . . . . . .
. . . . . . . . . . . . .
229 325 . .
Foot, Mtg Unit
176 736 . .
Screw, Mtg Foot
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
29 . . . .
. . . . . . . . .
PC3
PLG 18
. . .
. .
256 967
250 065
. .
. .
Circuit Card Assy, Front Pnl & Dspl W/Cover And Label
Plug, W/Leads (Voltage Feedback) RC2
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
PLG 21 . .
136 810 . .
Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
. . .
30 . . . . .
. . .
36
RC 21
S1
. .
. . . .
. . .
31 . . . . . . . . . . . . .
. . .
32 . . . . . . . . . . . . .
. . .
33 . . . . . . . . . . . . .
. . .
34 . . . . . . . . . . . . .
. . .
35 . . . .
C7, 8 . . .
. . . . . . . . . . . . .
167 640
244 920
. .
. .
Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . .
176 226
010 381
. .
. .
Insulator, Switch Power
Connector, Rectifier
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
182 707 . .
Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
251 594
222 488
. .
. .
Panel, Front W/Studs
Capacitor Assy,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181 245 . .
Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
37 . . . . . . . . . . . . . .
. . .
38 . . . . . . . . . . . . .
. . .
39 . . . . . . . . . . . . .
. . .
40 . . . . . . . . . . . . .
. . .
41 . . . . . . . . . . . . .
216 112
256 366
. .
. .
Fastener, Panel Receptacle Quick Access
Label, Controls
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181 169
186 621
. .
. .
Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
180 735 . .
Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
. . .
. . .
. . .
42
43
44
45
46
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
231 468
174 991
. .
. .
Nut, 375−32 .56Hex .22H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21
. . . . . . . . . . . . . . . . .
174 992
257 021
. .
. .
Knob, Pointer .840 Dia X .250 Id W/Spring Clip−.21
Label, Process
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
246 919 . .
Door, W/Quick Access Ball Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
47
48
. . . . . . . . . . . . .
. . . . . . . . . . . . .
251 151
175 138
. .
. .
Label, XMT 450 CC/CV
Box, Louver
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
256 496 . .
Circuit Card Assy, Control W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
49 . . . .
PC1 . . .
. . . . . . . .
. . . . . . . . .
PLG 2, 5,
7, 8, 10 . .
131 054 . .
Housing Plug+Pins (Service Kit) RC2, 5, 7, 8, 10 . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
4
1
1
2
1
2
1
2
2
1
1
2
1
1
1
1
1
3
2
1
2
2
2
1
2
1
1
1
1
2
1
1
2
1
1
1
1
1
4
4
1
1
1
1
4
2
1
4
4
1
1
5
OM-257 220 Page 50
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 12-1. Parts Assembly (Continued)
Quantity
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
PLG 3
PLG 4
PLG 6
PLG 9
. .
. . .
. . .
. . .
130 203 . .
Housing Plug+Pins (Service Kit) RC3
115 093 . .
Housing Plug+Pins (Service Kit) RC4
115 092 . .
Housing Plug+Pins (Service Kit) RC6
115 094 . .
Housing Plug+Pins (Service Kit) RC9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
50 . . . . . . . . . . . . .
. . .
51 . . . . . . . . . . . .
219 844 . .
Label, Warning Electric Shock/Exploding Parts-Wdle
+249 237 . .
Panel, Mtg PC Card s . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
. . .
52 . . . . .
RC14
T2
. . .
. . . .
. . .
53 . . . . . . . . . . . . .
. . .
54 . . . .
FM2 . . .
. . .
55 . . . . . . . . . . . . .
. . .
56 . . . . . . . . . . . . .
. . .
57 . . . . . . . . . . . . .
166 679
256 583
. .
. .
Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, Control Toroidal 400 VAC Pri 1160 VA 50 HZ . . . . . . . . . . . . . . . . .
180 105
183 918
. .
. .
Bracket, Mtg XFMR Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, Fan 24VDC 3000 RPM 43 Cfm W/10 Ohm Resistor . . . . . . . . . . . .
249 236
217 040
. .
. .
Bracket, Mtg Capacitor/PC Board/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Nylon M12 Thread Capacitor Mounting . . . . . . . . . . . . . . . . . . . . . . . . .
251 701 . .
Adapter, Nut Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
. . .
58
59
60
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . .
251 137
153 403
. .
. .
Windtunnel, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . .
255 855 . .
Bracket, Mtg Ct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
61
62
. . . . . . . . . . . . .
. . . .
CT1 . . .
177 547
181 271
. .
. .
Bushing, Snap−in Nyl Ct−Mount 1.093 Mtg Hole
XFMR, Current 500 Turn
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
63
64
. . . . . . . . . . . . .
. .
C3, 4, 5, 6 .
250 260
256 680
. .
. .
Insulator, Capacitor Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Capacitor 230/460 400VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
. . .
65
66
67
. . . . . . . . . . . . .
. . . .
. . . .
CB1
CB2
. . .
. . .
604 176
161 078
. .
. .
Rcpt, Str Dx Grd 2P3W 15A 125V *5−15R . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1P 7A 250VAC Frict . . . . . . . . . . . . . . . . .
083 432 . .
Supplementary Pro, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . .
. . .
68 . . . . . . . . . . . .
. . .
69 . . . . . . . . . . . . .
+256 890
252 637
. .
. .
Panel, Rear W/Studs 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear W/Aux & Gas MPa CC/CV 400V . . . . . . . . . . . . . . . . . . .
. . .
. . .
. . .
70
71
72
. . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . . .
217 297
185 526
. .
. .
Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock And Incorrect Input P . . . . . . . . . . . . . . . . .
010 311 . .
Clamp, Nyl .750 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . . .
. . .
73 . . . . . . . . . . . . .
. . .
74 . . . . .
Z1 . . . .
. . .
75 . . . . . . . . . . . . .
. . .
76 . . . . . . . . . . . . .
. . .
77 . . . . . . . . . . . .
179 930
180 029
. .
. .
Heat Sink, Power Module
Stabilizer, Output
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181 925
180 026
. .
. .
Insulator, Stabilizer Lead
Inductor, Input
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+249 105 . .
Windtunnel, Rh W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
78 . . . . . . . . . . . . .
. . .
79 . . . . .
W1 . . . .
. . .
80 . . . . . . . . . . . . .
. . .
81 . . . .
C1, 2 . . .
. . .
82 . . . . . . . . . . . . .
. . .
83 . . . .
PC2 . . .
. . .
84 . . . . . . . . . . . . .
. . .
85 . . . .
SR1 . . .
. . .
86 . . . .
RT2 . . .
. . .
87 . . .
PM1, 2 . .
. . .
88 . . . . . . . . . . . . .
. . .
89 . . . . . . . . . . . . .
. . .
90 . . . . . . . . . . . . .
. . .
91 . . . . . . . . . . . . .
. . .
92 . . . .
FM1 . . .
. . .
93 . . . . . . . . . . . . .
025 248
180 270
. .
. .
Stand−Off, Insul .250−20 X 1.250 Lg X .437 Thd
Contactor, Def Prp 40A 3P 24VAC Coil W/Boxlug
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
208 478
230 272
. .
. .
Capacitor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Polyp Film .34 UF 1000 VRMS +/−10% . . . . . . . . . . . . . . . . . . .
185 992
256 978
. .
. .
Bus Bar, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Circuit Card Assy, Interconnecting With Components . . . . . . . . . . . . .
185 208
184 260
. .
. .
Choke, Common Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
199 798 . .
Thermistor, NTC 30K Ohm @ 25 Deg C 18.00In 2500V . . . . . . . . . . . . . .
235 309
219 844
. .
. .
Kit, Transistor IGBT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock/Exploding Parts-Wdles . . . . . . . . . . . . . . . .
057 358 . .
Bushing, Snap−In Nyl 1.000 Id X 1.375 Mtg Hole . . . . . . . . . . . . . . . . . . . .
218 566
256 646
. .
. .
Gasket, Inductor Mounting E70 Ferrite Core
Inductor, DI/DT
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
175 084
251 220
. .
. .
Fan, Muffin 24VDC 3000 RPM 255 Cfm 6.378 Mtg Holes
Shroud, Fan
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . .
PLG 3 . .
. . . . . . . . .
250 048
130 203
. .
. .
Plug W/Leads Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Pins (Service Kit) RC3 On PC1
PLG 11 . .
131 056 . .
Housing Plug+Pins (Service Kit) RC7, 8
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . .
PLG 12
PLG 13
. . .
. . .
115 093
115 091
. .
. .
Housing Plug+Pins (Service Kit) RC2
Housing Plug+Pins (Service Kit) RC9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG 15, 16 .
115 094 . .
Housing Plug+Pins (Service Kit) RC1 On PC4, 5 . . . . . . . . . . . . . . . . . . . .
1
1
2
2
1
1
1
1
1
2
1
1
1
2
4
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
3
1
1
4
4
1
1
1
1
1
1
1
1
1
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-257 220 Page 51
Notes
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Warranty Questions?
Call
1-800-4-A-MILLER for your local
Miller distributor.
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Contact your distributor.
The expertise of the distributor and Miller is there to help you, every step of the way.
Effective January 1, 2012
(Equipment with a serial number preface of MC or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an
International distributor.
1.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
2.
3 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
3.
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
4.
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
5.
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
6.
90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
* M-Guns
* MIG Guns and Subarc (SAW) Guns
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns
Miller’s True Blue
®
Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)
2.
Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B.,
Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
miller_warr 2012-01
Owner’s Record
Please complete and retain with your personal records.
Serial/Style Number Model Name
Purchase Date
Distributor
Address
City
State
(Date which equipment was delivered to original customer.)
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Contact the Delivering Carrier to:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller
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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
©
2012 Miller Electric Mfg. Co. 2012−01
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit www.MillerWelds.com
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