Dimension 650 - Miller Welding

Dimension 650 - Miller Welding
OM-272 476A
2015−09
Processes
Multiprocess Welding
Description
Arc Welding Power Source
t
Dimension 650
CE
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller 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
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Features And Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Static Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Optional Low Open Circuit Voltage (OCV) Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Alternate Configuration Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − GTAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Typical Connection For GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. TIG Remote Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Lift-Arc TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − GMAW/FCAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . .
7-2. MIG Remote Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . .
7-4. MIG-Gas Output On Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. MIG-No Gas Output On Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SMAW/CAC-A OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Typical Connection For SMAW And CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Stick Remote Welding Mode - SMAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Stick-Output-On Welding Mode - SMAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Gouge Mode - CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
6
7
7
7
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
16
16
17
17
18
19
19
20
21
22
22
23
24
25
26
27
27
28
29
30
TABLE OF CONTENTS
SECTION 9 − SAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Typical Connection For SAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Subarc Welding Mode − SAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
31
31
32
33
33
33
34
35
36
38
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
Stock Number
Dimension 650 380/400V CE
907618
Council Directives:
• 2014/35/EU Low Voltage
• 2014/30/EU Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974­1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
September 24, 2015
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
273167A
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
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.
. Indicates special instructions.
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.
1-2. Arc Welding 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
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
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-263 655 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. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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 body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
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-263 655 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing 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.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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. Do
not stand in front of or behind the regulator when opening the 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.
OVERUSE can cause OVERHEATING
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.
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.
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.
H.F. RADIATION can cause interference.
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
D Sparks can cause fires — keep flammables away.
D
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.
D
D
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.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
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.
MOVING PARTS can injure.
ARC WELDING can cause interference.
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.
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.
D
D
D
D
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.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
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-263 655 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.)
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.
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 Combustibles, 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
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 Protection, 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).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. 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.
OM-263 655 Page 4
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.
SECTION 2 − DEFINITIONS
2-1. 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
When power is applied failed parts can explode or cause other parts to explode.
Safe89 2012−07
Notes
OM-272 476 Page 5
2-2. Miscellaneous Symbols And Definitions
A
Negative
Amperage
Voltage Sensing
Feeder
Gas Output
Alternating
Current (AC)
V
Voltage
Foot Control
On
Gas Metal Arc
Welding (GMAW)
Variable
Inductance
Output
Off
Input Voltage
Protective Earth
(Ground)
U2
Conventional
Load Voltage
Direct Current
(DC)
Panel
Constant Current
Rated Welding
Current
Arc Force
Increase
Flux Cored Arc
Welding (FCAW)
Circuit Breaker
Suitable For
Welding In An
Environment With
Increased Risk Of
Electric Shock
Line Connection
Three Phase
Static Frequency
ConverterTransformerRectifier
X
%
I2
Duty Cycle
Positive
Constant Voltage
Three Phase
Shielded Metal
Arc Welding
(SMAW)
Lift-Arc Operation
(GTAW)
Air Carbon Arc
Cutting (CAC-A)
Frame or Chassis
Remote
Notes
OM-272 476 Page 6
S
Percent
U1
IP
I1eff
Primary Voltage
Degree Of
Protection
Maximum Effective Supply Current
U0
Hz
I1max
Rated No Load
Voltage (OCV)
Hertz
Rated Maximum
Supply Current
Gas Tungsten Arc
Welding (GTAW)
Submerged Arc
Welding (SAW)
SECTION 3 − SPECIFICATIONS
3-1. Features And Benefits
LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input power fluctuation.
Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments.
Fan-On-Demandt 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 3-7).
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 5-2).
Lift-Arct TIG starts provide a contamination free weld without the use of high frequency in the Lift-Arc TIG Welding Mode (see Section 6-3).
Adaptive Hot Startt for Stick increases the output amperage at the start of a weld, eliminating electrode sticking in CC and Stick Welding Modes
(see Sections 8-2 and 8-3).
3-2. Arc Controls
DIG control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes in Stick Welding Modes (see Sections
8-2 and 8-3).
Inductance control influences the arc stiffness, bead width and appearance, and puddle fluidity in MIG Welding Modes (see Section 7-2).
3-3. 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.
3-4. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-7 and 4-8 for information on connecting input power.
A. Input Voltage And Current At Rated Output
Amperes Input At Rated
Output (50/60 Hz)
Output Ratings
Process
GTAW (Lift-Arc TIG)
GTAW (TIG)
SMAW (Stick)
GMAW/FCAW (Gas)
FCAW-S (No Gas)
SAW (Subarc)
CAC-A (Gouge)
Input Power
(Three Phase)
Current
(Amperes)
Voltage
(DC)
Duty Cycle
(%)
380 VAC
400 VAC
KW
KVA
650
34
100
39.1
37.4
24.2
25.8
750
34
60
45.3
43.2
28.2
29.8
815
34
25
49.4
46.9
30.6
32.5
650
44
100
49.9
47.4
30.9
32.8
750
44
60
57.9
55.0
35.8
38.2
650
44
100
49.9
47.4
30.9
32.8
750
44
60
57.9
55.0
35.8
38.2
815
44
25
63.5
60.2
39.1
41.8
0.32
0.39
0.055
0.21
0.45
0.53
0.152
0.37
Idle (Fan Off)
N/A
Idle (Fan On)
B. Output Range
Process
Output Range
Low Open Circuit Voltage (Uo)
Rated No-Load Voltage (Uo) − OCV
GTAW (Lift-Arc TIG)
10A−815A
N/A
12
GTAW (TIG)
10A−815A
12*
63
SMAW (Stick)
30A−815A
12*
CAC-A (Gouge)
30A−815A
12*
GMAW/FCAW (Gas)
10V−44V
N/A
FCAW-S (No Gas)
10V−44V
N/A
SAW (Subarc)
10V−65V
N/A
65
*See Section 5-3 for more information on Optional Low Open Circuit Voltage Mode.
OM-272 476 Page 7
3-5. Dimensions and Weight
Weight
168 lb (76.2 Kg)
28-3/16 in.
(716 mm)
24-3/16 in.
(614 mm)
30-1/4 in.
(768 mm)
11/16 in.
(17 mm)
16-11/16 in.
(406 mm)
31-5/8 in.
(803 mm)
14-1/4 in.
(362 mm)
269 320-A / / 269 319-A
3-6. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored, but is not intended to be used
for welding outside during precipitation unless sheltered.
IP23 2014−06
B. 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
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
C. 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 IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 14.74 mW (or the short−circuit power Ssc is greater than
10,854,131 VA). 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 system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
OM-272 476 Page 8
3-7. Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
700
If unit overheats, output stops, error
message is displayed (see Section
10-3), and cooling fan runs. Wait for
unit to cool and error message to
clear. Reduce amperage or duty
cycle before welding.
600
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
900
OUTPUT AMPERES
800
500
400
300
200
100
0
10
20
30
40
% DUTY CYCLE
50
60 70 80 90100
100% Duty Cycle At 650 Amperes
Continuous Welding
60% Duty Cycle At 750 Amperes
6 Minutes Welding
4 Minutes Resting
25% Duty Cycle At 815 Amperes
2 1/2 Minutes Welding
7 1/2 Minutes Resting
Overheating
A/V
OR
Reduce Duty Cycle
duty1 4/95 − SA-181 560 / 263 638-A
3-8. Static Output Characteristics
The static (output) characteristics of the welding power source can be described as flat during the GMAW and SAW processes and drooping during
the SMAW, CAC−A and GTAW processes. Static characteristics are also affected by control settings (including software), electrode, shielding gas,
weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welding power source.
OM-272 476 Page 9
SECTION 4 − INSTALLATION
4-1. Selecting A Location
Movement
!
Do not move or operate unit
where it could tip.
1
OR
2
Location And Airflow
3
18 in.
(460 mm)
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
loc_large 2015-04
Notes
OM-272 476 Page 10
4-2. 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***
150 ft
(45 m)
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
AWG (mm2)
300 ft
(90 m)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
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)
700
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
800
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
4x4/0 (4x120)
900
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
* 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.
( ) = mm2 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-L 2015−02
4-3. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
. See Section 4-4 for information on
connecting to weld output terminals, and Sections 6-1 thru 9-1 for
standard connection diagrams.
1
2
output term1 2015−02
OM-272 476 Page 11
4-4. Connecting Weld Output Cables
1
2
3
5
4
5
Tools Needed:
3/4 in. (19 mm)
!
!
!
269 322-A
Turn off power before connecting to
weld output terminals.
1
Weld Output Terminal
2
Supplied Weld Output Terminal Nut
nals to weld output terminal with nut and
bolt as shown, 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.
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
3
Supplied Weld Output Terminal Bolt
4
Copper Bar
5
Weld Cable Terminal
Use correct size weld cables (see
Section 4-2).
Remove supplied Bolt and nut from weld
output terminal. Secure weld cable termi-
4-5. Remote 14 Receptacle Information
A
B
K
Socket*
Socket Information
A
24 volts AC. Protected by supplementary protector CB2.
B
Contact closure to A completes 24 volts AC contactor control circuit.
C
Output to remote control; +10 volts DC in MIG
mode. 0 to +10 volts DC in other modes.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from remote control.
A/V
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 arc volts.
G
Circuit common for 24 volt AC circuit.
K
Chassis common.
J
I
24 VOLTS AC
H
C L N
D M
G
E F
Ref. 269 319-A
REMOTE
CONTROL
GND
*The remaining sockets are not used.
OM-272 476 Page 12
4-6. Supplementary Protector
1
2
3
115 V 20 Amp AC Receptacle
Supplementary Protector CB1
Supplementary Protector CB2
CB1 protects duplex receptacle.
CB2 protects 24 volts AC portion of
Remote 14 receptacle from
overload.
1
Press button to reset supplementary protector.
2
3
Ref 272 773-A
4-7. Electrical Service Guide
Elec Serv 2014−01
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.
CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral.
50/60 Hz Three Phase
Input Voltage (V)
380
400
Rated Maximum Supply Current I1max (A)
63.5
60.2
49.9
47.4
Time-Delay Fuses2
70
70
Normal Operating Fuses 3
100
90
8
8
138 (42)
153 (47)
8
8
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In
Min Input Conductor Size In
Amperes1
AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2014 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.
OM-272 476 Page 13
4-8. Connecting Input Power
3
= GND/PE
Earth Ground
10
12
9
U (L1)
8
V (L2)
W (L3)
6
2
11
1
1
3
4
U (L1)
8
7
V (L2)
W (L3)
6
Tools Needed:
3/8 in.
5
3/16 in.
Input12 2015−07 / Ref. 803 766-C / 272 784-A
OM-272 476 Page 14
4-8. Connecting Input Power (Continued)
!
!
!
Turn Off welding power source.
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 4-2. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
2
Input Power Cover
Remove screws and open cover.
Welding Power Source Input Power
Connections
3
Strain Relief (Customer Supplied)
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief. Tighten strain relief.
4
5
6
Input Power Connection Block
Welding Power Source Grounding
Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to machine grounding terminal
first.
7
8
Welding Power Source Line Terminals
Input Conductors U (L1), V (L2), W (L3)
Connect input conductors to welding power
source line terminals.
Close input power cover and secure with
screws.
Disconnect
Device
Connections
Input
Power
9
Disconnect Device (switch shown in
the OFF position)
10 Disconnect Device Grounding Terminal
11 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.
12 Over-Current Protection
Select type and size of over-current protection using Section 4-7 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
Input12 2015−07
Notes
OM-272 476 Page 15
SECTION 5 − GENERAL OPERATION
5-1. Front Panel
8
2
3
7
4
6
5
110
1
10
9
263561-B / Ref. 269321-B
. Weld
process operation sections describe functionality of the identified items
(See Sections 6-1 thru 8-4).
1
2
3
Remote 14 Receptacle
Left Display
Right Display
OM-272 476 Page 16
. The meters display the actual weld output
6
Arc Control
values after arc initiation and remains displayed for approximately three seconds
after the arc is broken.
7
Remote In Use Indicator
8
Mode Switch
4
Adjust Control
9
Weld Output Terminal (−)
5
Power Switch
10 Weld Output Terminal (+)
5-2. Mode Switch Settings
Switch Position
Process
Output Control
Panel Adjust
Remote Adjust
MIG−Gas
GMAW/FCAW
Output On
Volts
Volts
MIG−No Gas
FCAW−S
Output On
Volts
Volts
Stick
SMAW
Output On
Amps
No Remote Adjust Panel Only*
Gouge
CAC−A
Output On
Amps
No Remote Adjust Panel Only*
Lift-Arc TIG
GTAW
Output On
Amps
% Panel Amps
TIG
GTAW
Remote 14
Amps
% Panel Amps
Stick−Remote
SMAW
Remote 14
Amps
% Panel Amps
Subarc
SAW
Remote 14
Volts
Volts
MIG
GMAW/FCAW
Remote 14
Volts
Volts
*See Section 5-4 For Alternate Configuration Functions.
5-3.
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 Remote, Stick Output On, TIG Remote and Gouge
modes. When the unit is configured for low OCV operation, a low sensing voltage (approximately 12 VDC) is present between the electrode and
the workpiece prior to the electrode touching the workpiece. Consult a Factory Authorized Agent for information regarding how to configure unit
for low OCV welding operation.
OM-272 476 Page 17
5-4. Alternate Configuration Functions
The function of the remote control and panel meters can be changed on this machine.
To view or change the active configuration:
S Place the process selection switch into SMAW (Stick) Output-On mode.
S Quickly tap (press and release) the wire feeder gun trigger or remote output on-off switch 3 to 5 times within a few seconds to view the active
configuration.
S Repeat the tapping sequence to switch to the next configuration. The right meter will briefly display the new configuration before returning to
the preset display.
. Do not turn power off for at least 5 seconds to ensure the new configuration is saved. If supported, Preflow must be disabled on the wire
feeder to recognize gun trigger taps.
Alternate configurations are explained below. See Section 5-2 for default configuration operation.
C 1
SMAW (Stick), CAC-A (Gouge), and Stick Remote: The right
meter displays the preset amperage set with the panel Adjust
Control. When connected, the remote control sets the percentage of preset amperage. The Remote In Use indicator is lit while
the remote control is connected.
C 2
This is the default configuration as shipped from the factory.
SMAW (Stick) and CAC-A (Gouge): The remote amperage
control is ignored. The Remote In Use indicator is not lit. The
right meter displays the preset amperage.
Stick Remote: The right meter displays the preset amperage set
with the panel Adjust Control. When connected, the remote control sets the percentage of preset amperage. The Remote In Use
indicator is lit while the remote control is connected.
C 3
SMAW (Stick) and CAC-A (Gouge): The remote amperage
control is ignored. The Remote In Use indicator is not lit. The
right meter displays the preset amperage.
Stick Remote: The right meter displays the percentage of
preset amperage with a remote connected. The remote control sets the percentage of preset amperage. The Remote In
Use indicator is lit while the remote control is connected. Turning the panel Adjust Control will briefly display the preset amperage for 100%.
. Configurations 2 and 3 prevent a wire feeder from affecting the preset amperage of the Stick and Gouge Output-On modes.
OM-272 476 Page 18
SECTION 6 − GTAW OPERATION
6-1. Typical Connection For GTAW Process
4
3
1
2
269 325-A
6
5
7
8
!
Turn off power before making connections.
1
2
Foot Control
Positive (+) Weld Output Terminal
3
Remote 14 Receptacle
Connect desired remote control to Remote
14 receptacle if required.
4
Gas Cylinder
5
6
7
8
Gas Hose
Negative (−) Weld Output Terminal
TIG Torch
Workpiece
OM-272 476 Page 19
6-2. TIG Remote Welding Mode - GTAW Process
1
2
3
85
263 561-B
!
Weld terminals are energized
through the remote control in TIG
Remote welding mode.
1
2
3
Mode Switch
Right Display
Adjust Control
Setup
For typical system connections refer to
Section 6-1.
Rotate Mode Switch to TIG Remote position as shown.
The preset amperage is shown in the Right
Display.
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. The Remote In Use indicator
will be lit.
. 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-272 476 Page 20
6-3. Lift-Arc TIG Welding Mode - GTAW Process
1
2
12.0
3
4
85
263 561-B
6
“Touch”
1−2
Seconds
5
Do NOT Strike Like A Match!
!
Weld terminals are energized at all
times in Lift Arc TIG welding mode.
1
2
3
4
5
6
Mode Switch
Left Display
Right Display
Adjust Control
Workpiece
Tungsten Electrode
Setup
For typical system connections refer to
Section 6-1.
Rotate Mode Switch to LIFT-ARC TIG position as shown.
The open-circuit voltage is shown in the
Left Display. Preset amperage is shown in
the Right Display.
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.
. If a remote control is used for amper-
age adjustment, the adjustment will
function as a percentage of the preset
amperage. The Remote In Use indicator will be lit.
. For best results, firmly touch the tung-
sten 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.
OM-272 476 Page 21
SECTION 7 − GMAW/FCAW OPERATION
7-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process
9
1
2
3
8
7
4
269 323-A
6
5
!
Turn off power before making
connections.
5
Workpiece
6
Gun
7
Wire Feeder
1
Remote 14-Receptacle
2
Positive (+) Weld Output Terminal
3
Negative (−) Weld Output Terminal
8
Gas Hose
4
Ground Cable to Workpiece
9
Gas Cylinder
OM-272 476 Page 22
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).
7-2. MIG Remote Welding Mode - GMAW/FCAW Process
1
2
3
4
25.0
263 561-B
Rotate Mode Switch to MIG Remote position as shown.
!
Weld terminals are energized
through the remote control in MIG
Remote welding mode.
1
Mode Switch
The preset voltage is shown in the Left Display.
2
Left Display
Operation
3
Adjust Control
4
Arc Control
The Adjust Control is used to set desired
preset voltage.
Setup
For typical system connections refer to
Section 7-1.
. The preset voltage can be adjusted re-
motely at the wire feeder if the feeder
has a voltage control. This voltage control will override the Adjust Control of
preset voltage on the welding power
source. The Remote In Use indicator
will be lit.
Arc Control − Inductance
Inductance control allows the arc characteristics, soft versus stiff, to be changed for
specific applications and wires. The star
setting is good for most applications. Use
soft settings (0−25) to soften the arc and increase puddle fluidity. Use stiff settings
(0−25) to stiffen the arc and reduce puddle
fluidity.
OM-272 476 Page 23
7-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process
10
1
9
2
4
8
3
7
5
6
269 324-A
!
Turn off power before making connections.
1
2
3
4
5
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
Ground Cable to Workpiece
Workpiece
Voltage Sensing Clamp
OM-272 476 Page 24
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).
7-4. MIG-Gas Output On Welding Mode - GMAW/FCAW Process
1
2
3
4
25.0
263 561-B
!
Weld terminals are energized at all
times in MIG-Gas Output On welding mode.
1 Mode Switch
2 Left Display
3 Adjust Control
4 Arc Control
Setup
For typical system setup connections refer
to Section 7-3.
Rotate Mode Switch to MIG-Gas Output
On 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
Arc Control − Inductance
Inductance control allows the arc characteristics, soft versus stiff, to be changed for
specific applications and wires. The star
setting is good for most applications. Use
soft settings (0−25) to soften the arc and increase puddle fluidity. Use stiff settings
(0−25) to stiffen the arc and reduce puddle
fluidity.
pauses while the preset voltage is adjusted.
OM-272 476 Page 25
7-5. MIG-No Gas Output On Welding Mode - GMAW/FCAW Process
2
1
3
4
25.0
263 561-B
!
Weld terminals are energized at all
times in MIG-Gas Output On welding mode.
1 Mode Switch
2 Left Display
3 Adjust Control
4 Arc Control
Setup
For typical system setup connections refer
to Section 7-3.
OM-272 476 Page 26
Rotate Mode Switch to MIG-No Gas Output
On 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
Inductance control allows the arc characteristics, soft versus stiff, to be changed for
specific applications and wires. The star
setting is good for most applications. Use
soft settings (0−25) to soften the arc and increase puddle fluidity. Use stiff settings
(0−25) to stiffen the arc and reduce puddle
fluidity.
SECTION 8 − SMAW/CAC-A OPERATION
8-1. Typical Connection For SMAW And CAC-A Process
5
4
3
269 326-A
2
1
6
7
!
Turn off power before making connections.
cutting torch to positive weld output terminal.
Connect desired remote control to remote
14 receptacle as required.
1
Electrode Holder
(Carbon Arc)
2
3
4
5
6
7
For CAC-A process connect carbon arc
Electrode Holder
Positive (+) Weld Output Terminal
Remote 14 Receptacle
Compressed Air LIne
Negative (−) Weld Output Terminal
Workpiece
OM-272 476 Page 27
8-2. Stick Remote Welding Mode - SMAW Process
1
2
3
4
85
263 561-B
!
Weld terminals are energized
through the remote control in Stick
Remote welding mode.
1
Mode Switch
2
Right Display
3
Adjust Control
4
Arc Control
Setup
For typical system connections refer to
Section 8-1.
Rotate Mode Switch to Stick Remote position as shown.
The preset amperage is shown in the Right
Display with the Amps Indicator lit.
OM-272 476 Page 28
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. The Remote In Use indicator
will be lit.
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
Dig control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and electrodes. The star setting is good for most applications. Use soft
settings (0 to 25) for smooth running electrodes like E7018. Use stiff settings (0 to
25) for penetrating electrodes like E6010.
8-3. Stick-Output-On Welding Mode - SMAW Process
1
2
65.0
3
4
5
85
263 561-B
!
Weld terminals are energized at all
times in Stick-Output-On welding
mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
5 Arc Control
Setup
For typical system connections refer to
Section 8-1.
Rotate Mode Switch to Sick-Output-On
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.
Arc Control − Dig
Dig control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and electrodes. The star setting is good for most applications. Use soft
settings (0 to 25) for smooth running electrodes like E7018. Use stiff settings (0 to
25) for penetrating electrodes like E6010.
. For best results at the end of the weld,
pull back the electrode quickly to extinguish the arc.
OM-272 476 Page 29
8-4. Gouge Mode - CAC-A Process
1
2
65.0
3
4
350
263 561-B
!
Weld terminals are energized at all
times in Gouge mode.
1
Mode Switch
2
Left Display
3
Right Display
4
Adjust Control
OM-272 476 Page 30
Setup
For typical system connections refer to
Section 8-1.
Rotate Mode Switch to Gouge 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.
SECTION 9 − SAW OPERATION
9-1. Typical Connection For SAW Process
8
Power Source
Back View
7
9
10
5
6
1
Power Source
Front View
3
2
4
269 792-A
!
1
2
Turn off power before making connections.
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
3
4
5
6
Ground Cable to Workpiece
Workpiece
Wire Drive Assembly
10 Pin Motor Control Cord
7
8
9
10
Saw Control
Flux System
Flux Valve
14 Pin/115V Y−Cord
OM-272 476 Page 31
9-2. Subarc Welding Mode − SAW Process
1
2
3
25.0
263 561-B
!
Weld terminals are energized
through the remote control in Subarc welding mode.
1 Mode Switch
2 Left Display
3 Adjust Control
Setup
For typical system connections refer to
Section 9-1.
OM-272 476 Page 32
Welding Power Source
Rotate Mode Switch to Subarc position as
shown.
The preset voltage is shown in the Left Display.
SAW Controller
When using Miller Electric HDC DX controller, select Dimension 652 or SubArc DC
650 for power source selection.
. This product is not compatible with
digital series of subarc equipment.
Operation
Adjust preset voltage remotely at the SAW
controller. This voltage control will override
the Adjust Control of preset voltage on the
welding power source. The Remote In Use
indicator will be lit. See SAW controller
Owner’s Manual for additional information.
SECTION 10 − MAINTENANCE & TROUBLESHOOTING
10-1. Routine Maintenance
!
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Repair Or
Replace
Cracked
Cables
Replace
Damaged Or
Unreadable
Labels
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.
269 319-A
OM-272 476 Page 33
10-3. Help Displays
HELP
1
HELP
6
. All directions are in reference to the front
of the unit. All circuitry referred to is located inside the unit.
Help 1, 6, 7 Display
HELP
7
Indicates a malfunction in the primary power
circuit. If this display is shown, contact a Factory Authorized Service Agent.
HELP
2
Help 2 Display
HELP
3
Help 3 Display
HELP
4
Help 4 Display
5
Help 5 Display
HELP
HELP
HELP
OM-272 476 Page 34
8
25
Indicates a malfunction in the thermal protection circuitry. If this display is shown, contact
a Factory Authorized Service Agent.
Indicates the left side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 3-7). Operation will
continue when the unit has cooled.
Indicates the auxiliary circuit has overheated.
The unit has shut down to allow the fan to cool
it. Operation will continue when the unit has
cooled.
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 3-7). Operation will
continue when the unit has cooled.
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 3-7). Unit must be left on to
power the fan for cooling. Duty Cycle limit will
automatically reset when unit has cooled.
10-4. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-8).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-8).
Check for proper input power connections (see Section 4-8).
No weld output; meter display On.
Input voltage outside acceptable range of variation (see Section 4-7).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-7).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-2).
Clean and tighten all weld connections.
Check for correct polarity.
No 24 volts AC output at Remote 14
receptacle.
Reset supplementary protector CB2 (see Section 4-6).
No 115 volts AC output at duplex receptacle.
Reset supplementary protector CB1 (see Section 4-6).
Auxiliary circuit overheated. Allow unit to cool with fan on (see Section 3-7).
Notes
OM-272 476 Page 35
SECTION 11 − ELECTRICAL DIAGRAMS
Figure 11-1. Circuit Diagram For Dimension 650 CC/CV 380/400V
OM-272 476 Page 36
272 471-A
OM-272 476 Page 37
SECTION 12 − PARTS LIST
. Hardware is common and
not available unless listed.
13
14
12
15
11
10
9
20
21
22
19
23
8 (Fig 12-4)
34 (Fig 12-5)
18
17
24
7
6
25
16
28
27
26
5
4 (Fig 12-2)
3
29
30
31
2
32 (Fig 12-3)
1
18
33
272 811-A
Figure 12-1. Main Assembly
OM-272 476 Page 38
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . 1 . . . . . . . . . . . . . . 267295
. . 2 . . . . . . . . . . . . . . 263624
. . 3 . . FM1,FM2 . . 213072
. . 4 . . . . . . See Figure 12-2
. . 5 . . . . . . . . . . . . . . 176226
. . 6 . . . . RC2 . . . . 143976
. . 7 . . . . . S1 . . . . . 244920
. . 8 . . . . . . See Figure 12-4
. . 9 . . . . . . . . . . . . . . 272702
. . . . . . . . . . . . . . . . . . . 263620
. . . . . . . . . . . . . . . . . . . 234534
. . . . . . . . . . . . . . . . . . . 179310
. . . . . . . . . . . . . . . . . . . 175256
. . 10 . . . . . . . . . . . . . . 272564
. . . . . . . . . . . . . . . . . . . 263619
. . . . . . . . . . . . . . . . . . . 234534
. . . . . . . . . . . . . . . . . . . 179310
. . 11 . . . . . . . . . . . . . . 267339
. . 12 . . . . . . . . . . . . . +263606
. . 13 . . . . . . . . . . . . . . 272842
. . 14 . . . . . . . . . . . . . . 232914
. . 15 . . . . . . . . . . . . . . 266958
. . 16 . . . . . . . . . . . . . . 272492
. . 17 . . . . . . . . . . . . . +263610
. . 18 . . . . . . . . . . . . . . 272700
. . 19 . . . . . . . . . . . . . . 145743
. . 20 . . . . . W2 . . . . . 255744
. . 21 . . . . . . . . . . . . . . 272469
. . 22 . . . . . W1 . . . . . 180270
. . 23 . . . . FM3 . . . . 183918
. . 24 . . . . . . . . . . . . . . 263623
. . 25 . . . . . . . . . . . . . . 267340
. . 26 . . . . . T2 . . . . . 263618
. . 27 . . . . . . . . . . . . . . 269262
. . 28 . . . . . . . . . . . . . . 272493
. . 29 . . . . . . . . . . . . . . 263597
. . 30 . . . . . . . . . . . . . . 264243
. . 31 . . . . . . . . . . . . . . 269271
. . 32 . . . . . . See Figure 12-3
. . 33 . . . . PC2 . . . . 263632
. . 34 . . . . . . See Figure 12-5
. . . . . . . . . PLG1 . . . . 241172
. . . . . . PLG3, PLG4 241171
. . . . . . . . . PLG5 . . . . 241169
. . . . . . . . . PLG7 . . . . 241170
. . . . . PLG2, PLG11
. . . . . . PLG12, PLG13
. . . . . . PLG14, PLG70 131054
. . . RC11, RC12, RC13
. . . . . . . RC14, RC70 . 135635
. . . . . PLG10, PLG71 131204
. . . . . . RC10, RC71 . 131203
. . . . . PLG27, PLG28
. . . . . . PLG29, PLG30 241168
. . . . . . . . PLG19 . . . 115094
. . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fan, Muffin 115V 60Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . .
. . Panel, Front W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, Lh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side Rh (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, Side Folded Edge Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Miller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, General Precautionary Wordless Intl Small . . . . . . . . . . . . . . . . . .
. . . . Insulator (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side Lh (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, Side Folded Edge Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Miller (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, General Precautionary Wordless Intl Small (Not Shown) . . . . . .
. . Bracket, Corner Front (Casting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Top Folded Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Falling Equipment Can Injure−Wordles . . . . . . . . . . . . . . .
. . Seal, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Lift Eye Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . . . .
. . Lug, Univ W/Scr 600V 2−14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . .
. . Relay, Encl 24 VDC Spst 30A/300Vac 4Pin Flange Mtg . . . . . . . . . . . . . . .
. . Bracket, Mtg Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Contactor, Def Prp 40A 3P 24 VAC Coil W/Boxlug . . . . . . . . . . . . . . . . . . .
. . Motor, Fan 24VDC 3000 RPM 43 Cfm W/10 Ohm Resistor . . . . . . . . . . . .
. . Bracket, Mtg Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, HF Lead Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . XFMR, Control 380/460 VAC Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Base/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Base, W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bus Bar, Stabilizer/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Windtunnel/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, Rh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Rear W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
. . Housing Rcpt + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-272 476 Page 39
. Hardware is common and
1
not available unless listed.
2
15
14
3
4
13
5
6
7
8
12
9
11
10
269 850-A
Figure 12-2. Front Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Front Panel
. . 1 . . . . . . . . . . . . . +264279 . . Panel, Front W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 263561 . . Label, Nameplate Miller Dimension 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 231468 . . Nut, 375-32 .56Hex .22H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . . 245663 . . Knob, Encoder 1.250 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 231469 . . Nut, 500-28 .69Hex .28H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 213134 . . Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 174991 . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip-.21 . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 268891 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . . . 264114 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 11 . . . . . . . . . . . . . . 263560 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 263570 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 190512 . . Stand-off, No 6-32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . . 4
. . 14 . . . . . . . . . . . . . . 231470 . . Nut, Adapter Encoder Shaft Mtg 375-32 To 500-28 . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . PC1 . . . . 263562 . . Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG56 . . . 241167 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG59, PLG53 241168 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG60 . . . 241169 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG57 . . . 241170 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG55 . . . 241171 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG54 . . . 241172 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG58 . . . 269989 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . C13,C14 . . 267745 . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . VR1, VR2 . . 270076 . . Varistor, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 263611 . . Plug, W/Leads (Voltage Feedback) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 263613 . . Cable Assy, Current Feedback W/Ferrite Core . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 266925 . . Plugs, W/Leads & Current Xfmrs (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . CT1, CT2 . . 266798 . . . . XFMR, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 269893 . . Screw, 500−13x1.00 (Not Shown) Output Stud Hardware . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 222794 . . Nut, 500−13.75 Hex (Not Shown) Output Stud Hardware . . . . . . . . . . . . . 2
+ 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-272 476 Page 40
. Hardware is common and
not available unless listed.
3
1
4
5
2
6
12
7
11
8
9
10
269 852-A
Figure 12-3. Wind Tunnel, RH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Wind Tunnel, RH
. . 1 . . . . . . . . . . . . . . 263555 . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . RT1 . . . . 199798 . . Thermistor, Ntc 30K Ohm @ 25 Deg C 18.00in. 2500V . . . . . . . . . . . . . . . 1
. . 3 . . . . . Z1 . . . . . 263583 . . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . L1 . . . . . 272366 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 263578 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . . 2
. . 7 . . . . . . . . . . . . . . 170647 . . Bushing, Snap-in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 264199 . . Stand-off, Insul Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 268532 . . Nut, 375-16 .63Hex 1.13H Stl Pld Clr Coupling . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . PM1−PM4 . 263595 . . Kit, Transistor IGBT Module (Vishay) (2 Modules) . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 273362 . . Plugs, W/Leads (Gate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . SR1 . . . . 184260 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-272 476 Page 41
. Hardware is common and
not available unless listed.
16
15
14
13
10
11
12
1
17
9
18
2
3
4
5
6
8
7
272 803-A
Figure 12-4. Wind Tunnel, LH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Wind Tunnel, LH
. . 1 . . . . . . . . . . . . . +263569 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 245520 . . Bushing, Snap−In Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . 3
. . 3 . . . . . . . . . . . . . . 272700 . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109T Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . . . . 263571 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 6 . . . . HD1 . . . . 168829 . . Transducer, Current 1000A Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 264242 . . Bracket, Mtg Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 263559 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 196355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 10 . . . . . T1 . . . . . 269226 . . Xfmr Assy, Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 263556 . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 199840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 13 . . . D1−D4 . . . 269909 . . Kit, Diode Power Module (Vishay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 14 R1/C15,R2/C16 266955 . . Resistor/Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 15 . . . . RT2 . . . . 173632 . . Thermistor, Ntc 30K Ohm @ 25 Deg C 12.00 in. Lead . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 263554 . . Heat Sink, Rect Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . R3 . . . . . 270758 . . Resistor W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . C18, C19 . . 219191 . . Capacitor, Polyp Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+ 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-272 476 Page 42
. Hardware is common and
17
not available unless listed.
14
12
15
18
16
13
19
11
9
8
10
7
5
6
4
2
3
1
272 926-A
Figure 12-5. Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-5. Rear Panel Assembly
. . 1 . . . . PC7 . . . . 272312 . . Circuit Card Assy, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 272347 . . Stand−Off, No 10−32 X 1.500 Lg .375 Hex Nyl Fem . . . . . . . . . . . . . . . . . . 4
. . 3 . . . . . . . . . . . . . . 272486 . . Stand−Off, No 10−32 X 1.500 Lg .375 Hex Al Fem . . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . . 170647 . . Bushing, Snap−In Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 272479 . . Enclosure Assy, Primary Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . TE2 . . . . 272482 . . Block, Terminal 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . TE1 . . . . 198951 . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 272481 . . Bracket, Mtg Primary Block Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 265204 . . Ring, Aux Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 214918 . . Rcpt, Str Dx Grd 2P3W 20A 125V *5−20R . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . C17 . . . . 270072 . . Capacitor Assy, W/Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . CB2 . . . . 083432 . . Supplementary Pro, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . 1
. . 13 . . . . CB1 . . . . 093996 . . Supplementary Pro, Man Reset 1P 20A 250VAC Frict . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 272478 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 154022 . . Cover, Receptacle Duplex GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 272480 . . Door, Primary Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 272793 . . Spacer, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 . . . . . . . . . . . . . . 272792 . . Hinge, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . . . 272701 . . Label, Warning Input Conn/Elec Shock (Sym) . . . . . . . . . . . . . . . . . . . . . . . 2
+ 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-272 476 Page 43
Notes
Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
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, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Torches
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
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 twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/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
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* 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.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
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.)
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.
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 2015-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2015 Miller Electric Mfg. Co.
2015−01
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement