Miller CONTINUUM 500 W/INSIGHT CORE CE User manual

Miller CONTINUUM 500 W/INSIGHT CORE CE User manual
OM-272844A
2017−03
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Arc Welding Power Source
Continuum 350 And
Continuum 500
®
®
w/ Insight Coret
CE
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Advanced Manufacturing Systems
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 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. 350 Model Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. 500 Model Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Feeder Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Remote 10 Wire Feeder Control Receptacle RC2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Volt Sense Receptacle RC3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Supplementary Protector CB1 And Communication Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − RECOMMENDED SETUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Welding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. 30 Points Of Mechanics In MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Arc Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Basic Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Accessing Configuration Web Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
8
9
9
11
12
12
12
12
12
13
13
14
15
15
15
16
16
17
18
18
19
19
21
22
24
24
25
26
27
28
31
31
32
32
32
33
8-4. Arc Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Data Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Help Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Error Code Troubleshooting Description And Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − INSIGHT CORE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. License Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Downloading Connectivity Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Obtaining System IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Enabling Insight Core Through The Continuum’s Web Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Configuring The Network Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Verifying Network Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Determining Device Serial Number And License Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Registering Initial Device And Creating An Account . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. Registering Additional Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST FOR 350 AND 500 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
34
35
35
36
36
36
37
40
41
41
41
41
42
44
49
50
52
53
54
62
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
Continuum 350 CE
907645
Continuum 500 CE
907648
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 60974­10:2014 Arc Welding Equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
February 27, 2017
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
275623A
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
Stock Number
CONTINUUM 350 400V CE
CONTINUUM 500 400V CE
907645
907648
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.15
Health Ef­
fects
10 cm
0.09
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.14
3 cm
0.08
3 cm
0.18
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
6 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
277231A
Tony Samimi
Date tested:
2016-08-05
115 cm
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
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
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D 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-272844 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 can 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-272844 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 installation, 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-272844 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, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.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 30329-4027 (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 can 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-272844 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 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
OM-272844 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surOM-272844 Page 6
chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
OM-272844 Page 7
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held 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, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.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 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-272844 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
OM-277115 Page 9
Do not remove or paint over (cover) the label.
Safe20 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
Do not discard product with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
V
V
>5min
OM-277115 Page 10
V
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
Safe43 2012−05
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
V
Voltage
A
On
Off
Voltage Input
Arc Force
Protective Earth
(Ground)
Arc Force
X
%
Duty Cycle
Percent
Three Phase
Cold Jog (Inch)
Towards
Workpiece
Increase
U0
Hz
U1
IP
Rated Maximum
Supply Current
Purge By Gas
Locked
Process
Hertz
Arc Control
Primary Voltage
Direct Current
(DC)
Input
Degree Of
Protection
Positive
Read Instructions
S
Program
I1eff
Maximum Effective Supply Current
Constant Voltage
Line Connection
Constant Current
Time
Remote
I1max
Rated No Load
Voltage (OCV)
Suitable for Some
Hazardous
Locations
Alternating
Current (AC)
Cold Jog (Inch)
Away From
Workpiece
Amperage
I1
Primary Current
Wire Type
Negative
Variable
Inductance
Trigger Hold On
Indicator Light
Output
Gas Metal Arc
Welding (GMAW)
Wire Feed
U2
I2
Conventional
Load Voltage
Trigger Hold Off
Sequence
Rated Welding
Current
Gas Type
Three Phase
Static Frequency
Converter-Transfo
rmer-Rectifier
Trigger Hold
Off Indicator Light
OM-277115 Page 11
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. 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.
4-2. 350 Model Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-10 and 5-11 for information on
connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Input
Power
Rated Welding Output
Three
Phase
350 A @ 34 V DC,
100% Duty Cycle
Amperage
Range
CC Mode
Voltage
Range
CV Mode
Maximum
OpenCircuit
Voltage
20-400 A
10-44 V
75
Amperes Input
At Rated Load
Output 50/60 Hz,
Three-Phase
KVA
KW
380 V
400 V
380 V
400 V
380 V
400 V
21.8
(0-1A*)
20.8
(0-1A*)
14.4
(0.8*)
14.4
(0.8*)
13.8
(0.17*)
13.8
(0.17*)
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
4-3. 500 Model Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-10 and 5-11 for information on
connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Input
Power
Rated Welding Output
Three
Phase
500 A @ 40 V DC,
100% Duty Cycle
Amperage
Range
CC Mode
Voltage
Range
CV Mode
Maximum
OpenCircuit
Voltage
20-600 A
10-44 V
75
Amperes Input
At Rated Load
Output 50/60 Hz,
Three-Phase
KVA
KW
380 V
400 V
380 V
400 V
380 V
400 V
34.9
(0-1A*)
33.2
(0-1A*)
23.1
(0.8*)
23.1
(0.8*)
21.9
(0.17*)
21.9
(0.17*)
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
4-4. Dimensions And Weight
Hole Layout Dimensions
A
17.52 in. (445 mm)
B
17.33 in. (441 mm)
C
26.17 in. (665 mm)
D
16.09 in. (409 mm)
E
2.28 in. (58 mm)
F
.47 in. (12 mm)
G
.47 x 1 in.
(12 x 25mm)
Weight
**28.219 in.
(717 mm)
A
*27.188 in.
(691 mm)
D
E
24.891 in.
(632 mm)
G
C
B
350 Model:
130 lb (59 kg)
350 Model w/Aux Power:
139 lb (64 kg)
500 Model:
151 lb (69 kg)
500 Model w/Aux Power:
160 lb (73 kg)
Lifting Eye Weight Rating:
1000 lb (453 kg) Maximum
OM-272844 Page 12
F
18.188 in.
(462 mm)
*Height includes lifting eye
**Length includes boot
Ref. 278352-A
4-5. Static Characteristics
The static (output) characteristics of the welding power source can be described as flat during the GMAW process and drooping during the CAC−A
process. 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.
4-6. Environmental Specifications
A. IP Rating
IP Rating
IP23S
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.
IP23S 2014−06
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment does not comply with IEC 61000−3−12. If it is connected to a public low voltage system, it is the responsibility of the installer
or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment can be connected.
IEC/TS 61000-3-4 can be used to guide parties concerned by the installation of arc welding equipment with an input current greater than 16 A
in a low voltage network.
ce-emc 2 2014-07
C. Temperature Specifications
Operating Temperature Range
Storage Temperature Range
14 to 104 °F (−10 to 40°C)
−4 to 131 °F (−20 to 55°C)
Temp_2016- 07
D. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
OM-272844 Page 13
4-7. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
350 Model
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 350 Amperes
60% Duty Cycle At 400 Amperes
6 Minutes Welding
Continuous Welding
Overheating
4 Minutes Resting
A/V
0
15
OR
Reduce Duty Cycle
Minutes
500 Model
100% Duty Cycle At 500 Amperes
50% Duty Cycle At 600 Amperes
5 Minutes Welding
Continuous Welding
5 Minutes Resting
A/V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − SA-268 499-A / 268 498-A
OM-272844 Page 14
SECTION 5 − INSTALLATION
5-1. Selecting A Location
!
Movement
Do not move or operate
unit where it could tip.
3
1
OR
OR
2
Location And Airflow
!
4
18 in.
(460 mm)
Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
!
Do not stack units. Beware of tipping.
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
Hand Cart
Use cart or similar device to move unit.
4
Line Disconnect Device
Locate unit near correct input power supply.
18 in.
(460 mm)
Loc_continuum 2015-07
5-2. Feeder Location
1
1
Lifting Eye
When a feeder is installed on top of
power source, lift eye is inserted
through slot in feeder base.
Ref. 301199-TP1
OM-272844 Page 15
5-3. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
150 ft
(45 m)
200 ft
(60 m)
60 − 100%
Duty Cycle
AWG (mm2)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
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)
* 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
5-4. 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
. For welding output terminal connections see Sections 7-1 thru 7-5 for
typical connection processes.
1
2
Front View
Rear View
output term1 2015−02 / 259 119-D
OM-272844 Page 16
5-5. Connecting Weld Output Cables
!
Turn off power before connecting to
weld output tabs or receptacles.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
Ensure all connections are tight.
Tab Connection
. Do not place anything between weld
3
cable terminal and output tab. Make
sure that the surfaces of the weld cable
terminal and output tab are clean.
6
9
1
2
3
7
8
4
5
6
7
8
9
4
1
Front View
Tools Needed:
6
3/4 in. (19 mm) for output
terminal type connection
8
9
8
7
Negative (−) Tab
Positive (+) Tab
Correct Weld Cable Connection For
Single Feeder
Correct Weld Cable Connection For
2/0 And Larger Double Cables
Incorrect Weld Cable Connection
Weld Output Terminal Bolt
Nut
Weld Cable Terminal
Output Terminal
Remove supplied nut and bolt from weld
output terminal. Insert bolt through hole in
weld cable terminal and hole in weld output
terminal. Screw nut onto bolt until weld
cable terminal is tight against output terminal. Torque to 45-55 ft lb (61-75 N·m).
2/0 and larger double cables
5
2
Rear View
Ref. 259 119-D / 259 120-A
OM-272844 Page 17
5-6. Remote 10 Wire Feeder Control Receptacle RC2 Information
Socket
H
A
I
B
C
G
J
D
Socket Information
A
+50 Volts DC Common
B
+50 Volts DC Common
C
Voltage Sense
D
+50 Volts DC Power
E
+50 Volts DC Power
F
ENET Rx −
G
ENET Tx −
H
Drain
I
ENET Tx +
J
ENET Rx +
F
E
Ref. 259 119-D
5-7. Volt Sense Receptacle RC3 Information
Socket
Ref. 259 119-D
OM-272844 Page 18
Socket Information
A
Not Used
B
Volt Sense Negative
C
Not Used
D
Not Used
5-8. Supplementary Protector CB1 And Communication Panel
1
Ethernet Receptacle
Used for connecting a computer directly to the power source to access configuration web pages.
2
3
Supplementary Protector CB1
CB1 protects the wire feed motor
from overload. If CB1 opens, the
wire feeder does not work.
. Press button to reset breaker. If
breaker continues to open,
contact a Factory Authorized
Service Agent.
1
3
Wireless (WiFi) Antenna
Antenna for connecting to the internet via (WiFi) wireless connection if
selected during configuration.
2
Ref. 259 119-D
5-9. Connection Diagram
1
2
3
4
5
6
7
8
9
10
3
4
Welding Power Source
Wire Feeder
Gas Cylinder
Gas Hose
Feeder Cable
Electrode Cable
Work Cable
Volt Sense Lead
Welding Gun
Workpiece
. Shielding gas pressure not to
2
exceed 100 psi (689 kPa).
5
6
9
10
1
8
7
Ref. 269790-A
OM-272844 Page 19
Notes
OM-272844 Page 20
5-10. Electrical Service Guide
Elec Serv 2017-01
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.
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.
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
350 Model
50/60 Hz Three Phase
Input Voltage (V)
380
400
Input Amperes (A) At Rated Output
20.4
19.2
30
30
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses 2
Normal Operating Fuses
3
Min Input Conductor Size In AWG (mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG (mm2) 4
500 Model
40
35
10 (5.26)
10 (5.26)
214
(65)
238
(73)
10 (5.26)
10 (5.26)
50/60 Hz Three Phase
Input Voltage (V)
380
400
Input Amperes (A) At Rated Output
34.9
33.2
Time-Delay Fuses 2
50
50
3
70
70
8 (8.37)
8 (8.37)
180
(55)
198
(60)
8 (8.37)
8 (8.37)
Max Recommended Standard Fuse Rating In Amperes1
Normal Operating Fuses
Min Input Conductor Size In AWG
(mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG (mm2) 4
Reference: 2017 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) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. 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-272844 Page 21
5-11. Connecting 3-Phase Input Power
5
3
3
3
L1 (U)
8
= GND/PE Earth Ground
L2 (V)
6
L3 (W)
10
7
4
4
Input Power Contactor Connections
L1
L2
6
L3
9
1
2
Side View Of Unit
Tools Needed:
3/8 in.
3/16 in.
input5 2016−06 / 275971-A
OM-272844 Page 22
5-11. Connecting 3-Phase Input Power (Continued)
!
!
!
!
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.
NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be connected to any 3-phase input power between
230 and 575 VAC without removing cover to
relink the power source.
See rating label on unit and check input voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 5-10. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Welding Power Source Input Power
Connections
2
Strain Relief (Strain Relief Kit 274563
supplied with machine)
Install strain relief as explained in instructions
supplied with kit.
3
Welding Power Source Grounding
Terminal
4
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to machine grounding terminal first.
5
Welding Power Source Line Terminals
6
Input Conductors L1, L2, L3
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Reinstall top cover on welding power source.
Disconnect
Connections
7
8
9
Device
Input
Power
Disconnect Device (switch shown in the
OFF position)
Disconnect Device Grounding Terminal
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.
10 Over-Current Protection
Select type and size of over-current protection using Section 5-10 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
Input5 2016−06
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-272844 Page 23
SECTION 6 − RECOMMENDED SETUP PROCEDURES
6-1. Welding Circuit
. Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics.
1
2
3
4
5
6
7
1
Standard Welding Circuit
ECL
2
3
6
4
In pulse welding applications using
inverter power
sources,
cable
resistance can result in less than
satisfactory performance. In most
cases, a welding circuit length of 50 ft
(15 m) or less will provide satisfactory
performance with a standard welding
circuit connection.
The length of a welding circuit is
determined as follows:
5
Gun
Travel
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Volt Sense Lead
Wire Feeder
Workpiece
WCL
Welding Circuit = Electrode Cable
Length (ECL) + Work Cable Length
(WCL) + Workpiece Length (WL)
See Section 5-3 for weld cable size.
7
Current Flow Path
Variations in welding processes and
welding circuit resistance can affect
apparent voltage at the welding arc.
Voltage sensing can improve welding
performance by providing accurate
feedback to the welding power source.
1
It is important to connect the voltage
sensing lead as near to the weld as
possible, but not in the return current
path.
WL
Large Weld Structure
ECL
2
3
6
4
2
5
WCL
7
WL
Current Flow Path
Ref. 245 743-A / Ref. 259 144-A / Ref. 259 119-C
OM-272844 Page 24
6-2. Arranging Welding Cables To Reduce Welding Circuit Inductance
Bad
1
2
3
4
5
6
7
1
2
3
6
5
4
7
1
6
The arrangement of the cables has an
effect that is significant to the welding
properties. As an example, Accupulse
welding process can produce high
welding circuit inductance depending
on cable length and arrangement. This
can result in limited current rise during
droplet transfer into the welding puddle.
The sense lead is contained in the
feeder control cable and automatically
becomes
enabled
for
all
semi-automatic processes. The work
sense lead connects to the welding
power source 4-pin connector located
above the positive output terminal. This
work sense lead automatically compensates for work cable voltage drop when
connected to the welding power source.
Do not coil excess cables. Use cables
that are the appropriate length for the
application. Whenever using long weld
cables [longer than 50 ft (15 m)] try to
arrange positive and negative weld
cables together to reduce the magnetic
field surrounding the cables. Avoid
coupling the feeder and work sense
leads with the weld cables.
Better
3
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sense Lead
Wire Feeder
Workpiece
2
4
5
7
Best
1
3
6
2
4
7
5
Ref. 245 744-A / Ref. 259 144-A / Ref. 259 119-C
OM-272844 Page 25
6-3. 30 Points Of Mechanics In MIG Welding
30 Pts MIG − 2014-09
Primary Power
S
Check primary power connection at line disconnect switch or receptacle and/or cord plug.
S
Check primary power connection at welding power source.
Secondary Power
S
Check secondary weld output connections at welding power source.
S
Inspect condition and routing of positive weld cable to wire drive motor.
S
Check connection of positive weld cable to wire drive motor.
S
Inspect condition and routing of negative weld cable to fixture.
S
Check connection of negative weld cable to fixture.
S
Inspect condition of any rotary grounds, grounding shoes or other auxiliary grounds.
S
Check installation, routing and condition of welding gun.
Shielding Gas
S
Check gas hose connection to shielding gas supply regulator.
S
Check shielding gas flow rate.
S
Check gas hose routing.
S
Check gas hose connection at wire drive housing.
S
Check gun connection at wire drive and be sure O−rings seal at drive housing.
S
Check condition of gas diffuser.
S
Check condition of nozzle.
S
Check O-ring for proper sealing at nozzle.
Welding Wire
S
Inspect condition of de-reeler. Check for wear at quick-connect coupling and replace if necessary.
S
Check placement of payoff pack or drum for smooth feed path.
S
Inspect condition and routing of input conduit.
S
Check installation of quick-connect coupling at rear of wire drive so that it does not contact drive rolls. Check for wear and replace if necessary.
S
Check drive rolls and replace if worn.
S
Check for drive roll tension setting.
S
Check intermediate guide for proper size to match wire size and replace if worn.
S
Check for proper length of liner at both ends and be sure it is cut without burrs.
S
Check liner for proper size to match wire size.
S
Check liner for wear and clean out to prevent plugging.
S
Check contact tip for proper size to match wire size.
S
Check contact tip for wear and change at regular intervals.
S
Check contact tip for a tight fit and secure installation at gun.
OM-272844 Page 26
6-4. Arc Blow
Arc blow is the deflection of the welding arc from its normal path due to magnetic forces. This condition is usually encountered in direct current welding of
magnetic materials, such as iron and nickel. Arc blow can happen in alternating current welding under certain conditions, but these cases are rare and
the intensity of the arc blow is always less severe. Direct current flowing through the electrode and base metal will set up a magnetic field around the
electrode. This magnetic field tends to deflect the arc to the side at times, but usually the arc deflects either forward or backwards along the joint.
Back blow is encountered when welding toward the work cable connection on a workpiece near the end of a joint or into a corner. Forward blow is
encountered when welding away from the work cable connection on a workpiece at the start of a joint. In general, arc blow is the result of two basic
conditions:
1.
The change of current flow direction as it enters the work and is conducted toward the work cable.
2.
The asymmetric arrangement of magnetic material around the arc, a condition that normally exists when welding is performed near the end of
ferromagnetic materials.
Although arc blow cannot always be completely eliminated, it can be controlled or reduced to an acceptable level through knowledge of the two conditions listed above.
Except in cases where arc blow is unusually severe, certain steps can be taken to eliminate or reduces its severity. Some or all of the following steps
may be necessary:
*
Place work cable connection as far as possible from joints to be welded.
*
If back blow is the problem, place the work cable connection at the start of the joint to be welded and weld toward a heavy tack weld.
*
If forward blow is the problem, place the work cable connection at the end of the joint to be welded.
*
Position electrode angle so that arc force counteracts arc blow.
*
Use the shortest possible arc that maintains good welding practices (this helps arc force to counteract arc blow).
*
Reduce welding current if possible.
*
Weld toward a heavy tack weld or runoff tab.
*
Use the back step sequence of welding.
*
Change to an AC welding operation which may require a change in electrode classification.
*
Wrap the work cable around the workpiece in the direction that sets up a magnetic field to counteract the magnetic field causing the arc blow.
Notes
OM-272844 Page 27
6-5. Basic Welding Troubleshooting
Listed below are some problems, causes and remedies related to welding operations; however, this list does not contain every possible condition that
could be encountered in welding.
Trouble
No weld output; unit completely
inoperative.
Probable Cause
Remedy
Line disconnect switch in Off position.
Place switch in On position.
Power source switch in Off position.
Place switch in On position.
Primary power fuse blown or circuit breaker
tripped.
Replace fuse or reset circuit breaker and check input voltage.
Weld output is present, but wire stops Wire feeder protective fuse blown or circuit breaker
feeding while welding.
tripped.
Replace fuse or reset circuit breaker and find overload condition.
OM-272844 Page 28
Wire feeder drive rolls misaligned.
Align drive rolls.
Wrong size drive rolls.
Replace with proper size drive rolls.
Too much or too little drive roll pressure.
Adjust drive roll pressure.
Too much tension set at wire spool.
Reduce wire spool tension.
Restriction in unspooler or drum adapter.
Replace unspooler or repair restriction.
Feeder motor burnt out.
Test motor and replace if necessary.
Gun liner dirty or restricted.
Remove gun liner and clean or replace.
Wrong type or size of liner.
Install proper size liner.
Broken or damaged gun or torch.
Replace faulty parts.
Contact tip opening restricted.
Replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Sharp bends or kinks in gun cable or liner.
Straighten gun cable and/or replace liner.
Gun overheating.
Use gun with proper amperage rating.
Wrong size wire.
Match wire size to liner and contact tip.
Guides rubbing on drive rolls.
Adjust or position guides properly.
Drive rolls jammed.
Remove foreign object from gears.
Motor cable disconnected or damaged.
Connect, repair or replace motor cable.
Trouble
Porosity in weld.
Excessive spatter.
Probable Cause
Remedy
Dirty base metal, heavy oxides, mill scale, oil, etc.
Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Regulator/flowmeter faulty.
Adjust or replace regulator/flowmeter.
Gas cylinder valve closed.
Open gas cylinder valve.
Gas regulator diaphragm defective.
Replace regulator.
Flowmeter cracked or broken.
Repair or replace flowmeter.
Gas hose disconnected or leaking.
Connect or replace gas hose.
Too much or too little gas flow.
Adjust for proper gas flow.
Moisture in shielding gas.
Replace gas cylinder or supply.
Wrong gas for wire type or transfer mode.
Use correct shielding gas.
Feeder gas solenoid faulty.
Replace solenoid.
Gun or outlet cable leaking.
Repair or replace faulty parts.
Wire feed speed setting too high.
Reduce wire feed speed.
Contact tip extends too far out of nozzle.
Adjust or replace parts (max distance should not
exceed 1/8 in (3.2 mm).
Nozzle to work distance too large.
Reduce nozzle to work distance.
Incorrect gun or torch angle.
Set proper gun angle (porosity or dirty welds mean
gun angle is too large).
Nozzle restriction.
Clean off spatter or remove restriction.
Breeze or drafts in weld zone.
Shield weld zone from drafts.
Low shielding gas cylinder pressure.
Replace gas cylinder.
Gas leak at gun to feeder connection.
Properly install gun or replace O-rings at gun
connector.
Voltage set too high.
Reduce voltage setting (reduce trim or arc adjust
for pulse welding).
Incorrect gun or torch angle.
Set proper gun angle.
Too much or too little gas flow.
Adjust for proper gas flow.
Wrong gas for wire type or transfer mode.
Use correct shielding gas.
Wrong electrode wire type or size.
Use proper electrode wire.
Wrong inductance setting.
Adjust inductance.
Electrode wire dirty or old.
Replace with new electrode wire.
Oily or dirty base metal.
Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Excessive wire stick-out or nozzle to work distance Adjust wire stick-out or reduce nozzle to work
too great.
distance.
Wrong transfer mode.
Set proper transfer mode.
Travel speed too slow.
Increase travel speed so that arc is on leading edge
of weld puddle.
OM-272844 Page 29
Trouble
Wandering, hunting or erratic arc.
Probable Cause
Replace unspooler or repair restriction.
Dirty or worn gun liner or inlet cable.
Remove gun liner or inlet cable and clean or replace.
Sharp bends or kinks in gun cable or liner.
Straighten gun cable and/or replace liner.
Loose or worn contact tip.
Tighten or replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Gun overheating.
Use gun with proper amperage rating.
Loose power cables or other electrical
connections.
Tighten, repair or replace connections or cables,
also check all rotary or brush type connections.
Incorrect gun or torch angle.
Set proper gun angle.
Too much or too little gas flow.
Adjust for proper gas flow.
Moisture in shielding gas.
Replace gas cylinder or supply.
Wrong gas for wire type or transfer mode.
Use correct shielding gas.
Wrong program selection for pulse welding.
Make proper program selection.
Improper or unsteady analog command from robot
controller.
Check signal from robot controller (as a troubleshooting aid go to power source control of voltage
and wire speed).
Gun or outlet cable leaking.
Repair or replace faulty parts.
Incorrect nozzle to work distance.
Set proper distance [3/8 in to 5/8 in (9.5 to 15.9 mm)
for short arc, 5/8 in to 1 in (15.9 to 25.4 mm) for
pulse welding, and 3/4 in to 1-1/4 in (19.1 to 31.8
mm) for spray welding].
Voltage sensing leads open or shorted.
Repair or replace voltage sense leads.
High frequency noise in the area.
Be sure proper grounding methods are followed
when TIG or plasma equipment is used in the area.
Arc blow.
See Section 6-4.
Drive motor tachometer or motor cable open or
shorted.
Check drive motor tachometer and cables, and repair or replace.
Wrong size drive rolls.
Replace with proper size drive rolls.
Too much or too little drive roll pressure.
Adjust drive roll pressure.
Welding wire burns back to contact tip at Restriction in wire feed system.
the start of a weld.
Worn drive rolls.
Check inlet cable, gun liner and wire guides.
Replace drive rolls.
Wrong size drive rolls.
Replace with proper size drive rolls.
Improper start parameters.
Adjust start parameters.
Worn contact tip.
Replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Not enough cast in welding wire.
Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip Restriction in wire feed system.
during welding.
Worn drive rolls.
Check inlet cable, gun liner and wire guides.
Replace drive rolls.
Wrong size drive rolls.
Replace with proper size drive rolls.
Too much or too little drive roll pressure.
Adjust drive roll pressure.
Worn contact tip.
Replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Not enough cast in welding wire.
Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip at Welding power source output not shutting off.
the end of a weld.
Burnback setting too high or too long.
OM-272844 Page 30
Remedy
Restriction in unspooler or drum adapter.
Make sure all switches are in correct position,
repair power source if necessary.
Adjust burnback setting or turn off completely.
SECTION 7 − OPERATION
7-1. Operator Controls
1
Power Switch
Turns unit On or Off.
2
Power On LED
Power LED illuminates when unit is
energized.
3
Output On LED
Output LED illuminates when weld
output is energized.
4
Error LED
On Solid−
Unit has overheated and weld output has been disabled. Allow unit to
cool to operating temperature. Error LED will turn off and welding
may resume.
1
Blinking−
A system error has occurred. Use
the User Interface to determine the
source of the error as well as possible solutions. Follow on-screen instructions to clear the error. When
the error has been cleared the Error
LED will stop blinking and welding
may resume.
. After turning unit off, wait until
Power ON LED is off before
turning unit back on. Cycling
power too quickly can cause
software issues on power up.
2
3
4
Ref. 257 195-G
OM-272844 Page 31
SECTION 8 − CONFIGURATION
8-1. Accessing Configuration Web Pages
To access the power source configuration webpages you will need the optional communication panel (See Section 5-8). Connect a PC directly to the
jack on the communication panel with a CAT5 or CAT6 Ethernet cable.
Enter the default IP address, 169.254.0.2, into a web browser and the welder configuration web pages will open to the Home screen.
8-2. Home Screen
1
2
3
5
4
6
8
9
1 Navigation Bar
Select Home, Setup, Arc Management, Data
Management, or Help screens.
2 Information Bar
Displays general information on power
source, location, asset number, serial number, and display language.
3 Power Source Information
Displays power source information. Edit button allows these parameters to be changed.
4 Active Program
OM-272844 Page 32
7
Displays the program number, process, wire
size and alloy, and gas. Edit button allows
these parameters to be changed.
5 Weld Outputs (Live)
Displays the weld output conditions of the
power source and feeder in real time.
6 Commands
Displays current user changeable commands. Depending on the weld process being
used these commands will vary. Edit button
allows parameters to be changed.
7
Last Weld
Displays the voltage and amperage used during the last weld made.
8
Productivity
Displays arc time, the amount of wire used,
and the amount of wire remaining.
9
Active Error
Displays any active error messages. View
Error Log button will display a list of previous
errors and the time at which they occurred.
8-3. Setup Screen
2
1
3
5
4
6
8
7
9
10
1
Information Bar
Displays general information on welding power source, location, asset number, serial number, and display language.
2
Purge Time
Displays the length of time gas will flow when
the purge button is pressed. Edit button allows
time length to be changed.
3
Enabled Errors
Displays which system errors are enabled.
Click Edit to enable or disable system errors.
4
Jog Speed
Displays the minimum and maximum Jog
speeds in inches per minute (IPM). Edit button
allows minimum and maximum jog speed setting to be changed for forward and reverse jog.
5
Ethernet Settings
Edit button allows user to change connectivity
settings.
6
Data Connections
Displays which data connections are enabled
or disabled.
7
WiFi Settings
Edit button allows user to change WiFi
Settings.
8
Auto Thread
Displays the Load Rate in inches per minute
(IPM) and Torch Length (Inches) to determine
the length of time for Auto Threading. Edit button allows these parameters to be changed.
9
Status
Displays the status of Insight software. Edit
button allows that status to be changed.
10 Weld Cable Setup
Displays length and diameter of positive and
negative weld leads, torch, and voltage feedback (VFB) method that are selected. Edit button allows these parameters to be changed.
OM-272844 Page 33
8-4. Arc Management Screen
1
3
2
6
4
5
7
1 Active Program
Displays the program number, process, wire
size and alloy, and gas. Edit button allows
these parameters to be changed.
2 Commands
Displays current user changeable commands.
Depending on the weld process being used
these commands will vary. Edit button allows
parameters to be changed.
3 Weld Sequence
Displays active weld sequence parameters.
OM-272844 Page 34
Edit button allows changes to these parameters.
4
Lock Status
Displays the current status of system locks.
Edit button allows the lock configuration to be
changed.
5
Program Enable
Edit button will allow user to select which programs are available for use.
6
Weld Processes
Displays available weld processes. Edit button allows processes to be enabled or disabled.
7
Advanced Triggers
Displays the current status of advanced trigger modes. Edit button allows status of trigger
modes to be changed.
8-5. Data Management Screen
1
4
1 Productivity
Displays arc time and wire used in inches and
pounds. Click Reset Data to reset productivity
data.
2 Lifetime Information
Displays total arc time, arc starts, and wire
used over lifetime of unit.
3 Software Information
Displays the software revision.
2
3
5
6
Factory Reset button will take user to a Factory Reset screen. Read and follow all instructions on Factory Reset screen to perform a
Factory Reset.
4
Error Log
Displays the last error experienced by the
system.
View button displays a list of previous errors
and the time at which they occurred.
5
System Log
Displays the last entry into the system log.
View button displays a list of the entries made
to the system log and the time at which they
occurred.
6
Wire Usage
Displays the amount of wire used, the amount
remaining, and the date the spool was started.
Click Reset Data when starting a new spool.
8-6. Help Screen
. The Help
Screen contains
three drop down menus
which contain the features
on the Setup, Arc Management and Data Management
screens.
1
2
3
1
Setup Information
Drop−Down Menu
2
Arc Management
Drop−Down Menu
3
Data Management
Drop−Down Menu
OM-272844 Page 35
SECTION 9 − MAINTENANCE & TROUBLESHOOTING
9-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
Every
6
Months
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
l = Replace
Reference
l Unreadable Labels
~ Weld Terminals
nl Weld Cables
nl Gun Cables
nl Cords
nl Cracked Parts
~ Weld Connections
n Tighten Weld Cable
Connections
OR
~ Inside Unit
9-2. 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.
Ref. 259 119-D
OM-272844 Page 36
9-3. Error Code Troubleshooting Description And Tables
LED Display
Message
WELD
WAIT
Message
Type
LCD Display Message
LCD Solution
Message
LCD Error Log
Message
ERROR
Unit was not ready for a weld sequence
Press button to clear error
Weld Wait Error
ERROR
Welding power source has overheated
Allow unit too cool then cycle
power
Overtemp Error
ERROR
Emergency stop activated
Reset the emergency stop
button
E Stop
OVER CURRENT
ERROR
Welding power source primary draw
too high
Check input primary then cycle power
Primary Overcurrent
CYCLE POWER
MESSAGE
The unit requires a power cycle
Cycle power on the power
source
Cycle Power Error
ERR OVERTEMP
E STOP
OVER POWER
ERROR
SLF TST ERR
ERROR
Welder failed self test
Cycle power on the power
source
Self Test Error
ERR INPT PWR
ERROR
Input Power Problem
Ensure your primary voltage is
correct
Input Power Problem
ERR
ERROR
Feeder Power Problem
Cycle power on the power
source
Feeder Power Problem
ERR AUX PWR
ERROR
AUX Power Problem
Cycle power on the power
source
AUX Power Problem
ERR
ERROR
Thermal System Problem
Cycle power on the power
source
Thermal System Problem
ERR PWR SRC
ERROR
Welder Power Source Problem
Cycle power on the power
source
Power Source Problem
ERR
WFS
ERROR
Actual WFS does not match command
Press button to clear error
Wire Speed Error
ERR
STRT
ERROR
Trigger held too long without arc
Press button to clear error
Arc Start Error
ERR
STOP
ERROR
Potential obstruction in wire feed system
Check wire feed and wire
drive systems
Arc Stop Error
ERR GAS FLW
ERROR
No gas flow to the gun
Check gas connections
Gas Flow Error
ERR COOL FLW
ERROR
No coolant flow in water system
Check water cooling system
Coolant Flow Error
ERR GND CRNT
ERROR
Weld current detected in earth ground
Check and repair feeder weld
connections
Earth Ground Current Error
ERR WIR STUK
ERROR
Wire stick to workpiece at the end of
the weld
Break/Cut wire away from
workpiece
Wire Stuck Error
ERR
ERROR
Arc Outage occurred
Check wire feeder and power
source
Arc Outage Error
ERR TRG STUK
ERROR
Trigger held during power up
Release trigger and cycle
power
Trigger Stuck Error
ERR SOFTWARE
ERROR
Incompatible software detected in the
system
Update software
Incompatible Software Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder EEPROM Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder USART1 Error
ERR COMM FDR
ERROR
Feeder Lost Comms to Arc Controller
Check the control cable
Feeder lost comms to AC
ERR FDR PWR
ERROR
Feeder power fault
Cycle power on the power
source
Feeder bus overcurrent error
ERR FDR PWR
ERROR
Feeder power fault
Cycle power on the power
source
Feeder bus current fault
ERR FDR RLY
ERROR
Feeder power relay stuck open
Cycle power on the power
source
Feeder relay stuck open
ERR FDR ETH
ERROR
Feeder Ethernet switch malfunction
Cycle power on the power
source
Feeder Ethernet switch error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder USART3 Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder USART2 Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder SPI2 Error
ERR FDR TACH
ERROR
Feeder has lost tachometer wire
speed feedback
FDR
THERM
ARC
Feeder lost tach signal error
OM-272844 Page 37
LED Display
Message
Message
Type
LCD Display Message
LCD Solution
Message
LCD Error Log
Message
ERR BTN STUK
ERROR
Button on UI stuck
Make sure all buttons are
clear
UI Button Stuck
ERR COMM UI
ERROR
UI Lost Comms to the Sequencer
Check the control cable
UI lost comms to Seq
FACTORY RST
ERROR
Factory Reset Complete
Cycle power on the power
source
Factory Reset
UNUSED 218
ERROR
Unused Error #218
Cycle power on the power
source
Unused Error #218
ERR INPT PWR
ERROR
Must use three phase primary power
Check primary connections
Single Phase Error
ERR INPT PWR
ERROR
Primary input voltage too high
Check primary connections
High Input Voltage Error
ERR INPT PWR
ERROR
Primary input voltage too low
Check primary connections
Low Input Voltage Error
UNUSED 222
ERROR
Unused Error #222
Cycle power on the power
source
Unused Error #222
ERR FEEDER
ERROR
Feeder input voltage too high
Cycle power on the power
source
Feeder Voltage High Error
ERR FEEDER
ERROR
Feeder input voltage too low
Cycle power on the power
source
Feeder Voltage Low Error
UNUSED 225
ERROR
Unused Error #225
Cycle power on the power
source
Unused Error #225
ERR AUX PWR
ERROR
Too much current draw from AUX
power port
Cycle power on the power
source
AUX Power Overcurrent Error
ERR AUX PWR
ERROR
AUX power module overheated
Cycle power on the power
source
AUX Power Overtemp Error
ERR AUX PWR
ERROR
AUX power voltage too high
Cycle power on the power
source
AUX Voltage High Error
ERR AUX PWR
ERROR
AUX power voltage too low
Cycle power on the power
source
AUX Voltage Low Error
UNUSED 230
ERROR
Unused Error #230
Cycle power on the power
source
Unused Error #230
ERR THERM 1
ERROR
Thermistor 1 overtemp
Allow welder to cool then cycle power
THERM1 Overtemp Error
ERR THERM 2
ERROR
Thermistor 2 overtemp
Allow welder to cool then cycle power
THERM2 Overtemp Error
ERR THERM 3
ERROR
Thermistor 3 overtemp
Allow welder to cool then cycle power
THERM3 Overtemp Error
ERR THERM 1
ERROR
Thermistor 1 shorted
Cycle power on the power
source
THERM1 Shorted Error
ERR THERM 2
ERROR
Thermistor 2 shorted
Cycle power on the power
source
THERM2 Shorted Error
ERR THERM 3
ERROR
Thermistor 3 shorted
Cycle power on the power
source
THERM3 Shorted Error
ERR THERM 1
ERROR
Thermistor 1 open
Cycle power on the power
source
THERM1 Open Error
ERR THERM 2
ERROR
Thermistor 2 open
Cycle power on the power
source
THERM2 Open Error
ERR THERM 3
ERROR
Thermistor 3 open
Cycle power on the power
source
THERM3 Open Error
UNUSED 240
ERROR
Unused Error #240
Cycle power on the power
source
Unused Error #240
ERR PWR SRC
ERROR
Invalid device configuration
Cycle power on the power
source
Invalid Power Source Config
ERR PWR SRC
ERROR
Output current sensor malfunction
Cycle power on the power
source
Output Current Sensor Error
ERR PWR SRC
ERROR
Inverter −15V power supply out of regulation
Cycle power on the power
source
Inverter −15V Power Error
ERR PWR SRC
ERROR
Inverter +15V power supply out of regulation
Cycle power on the power
source
Inverter +15V Power Error
ERR PWR SRC
ERROR
Invalid inverter device configuration
Cycle power on the power
source
Invalid Inverter Config
ERR PWR SRC
ERROR
Inverter primary CT error
Cycle power on the power
source
Inverter Primary CT Error
OM-272844 Page 38
LED Display
Message
Message
Type
LCD Display Message
LCD Solution
Message
LCD Error Log
Message
ERR PWR SRC
ERROR
Boost fault
Cycle power on the power
source
Boost Fault Error
ERR PWR SRC
ERROR
Boost contactor error
Cycle power on the power
source
Boost Contactor Error
ERR PWR SRC
ERROR
Boost CS1 current error
Cycle power on the power
source
Boost CS1 Error
ERR PWR SRC
ERROR
Boost CS2 current error
Cycle power on the power
source
Boost CS2 Error
ERR PWR SRC
ERROR
Boost CS3 current error
Cycle power on the power
source
Boost CS3 Error
ERR PWR SRC
ERROR
Boost CS4 current error
Cycle power on the power
source
Boost CS4 Error
ERR PWR SRC
ERROR
Boost current balance error
Cycle power on the power
source
Boost Current Balance Error
ERR PWR SRC
ERROR
Boost overcurrent error
Cycle power on the power
source
Boost Overcurrent Error
ERR PWR SRC
ERROR
Boost precharge error
Cycle power on the power
source
Boost Precharge Error
ERR PWR SRC
ERROR
Boost bus balance error
Cycle power on the power
source
Boost Bus Balance Error
ERR PWR SRC
ERROR
Boost bottom bus cap voltage high
Cycle power on the power
source
Boost Bottom Bus Cap V High
ERR PWR SRC
ERROR
Boost top bus cap voltage high
Cycle power on the power
source
Boost Top Bus Cap V High
ERR PWR SRC
ERROR
Invalid boost device configuration
Cycle power on the power
source
Invalid Boost Config
ERR PWR SRC
ERROR
Boost −15V power supply out of regulation
Cycle power on the power
source
Boost −15V Power Error
ERR PWR SRC
ERROR
Boost −24V power supply out of regulation
Cycle power on the power
source
Boost −24V Power Error
ERR PWR SRC
ERROR
Boost +15V power supply out of regulation
Cycle power on the power
source
Boost +15V Power Error
WRN VSNS LOS
WARNING
Lost volt sense lead feedback
Inspect volt sense lead for
break
Vsense Fallback Warning
ERR UNKNOWN
ERROR
An unknown error has occurred
Update software
Unknown Error
OM-272844 Page 39
9-4. Troubleshooting
Trouble
No weld output; completely inoperative
Remedy
Place line disconnect in On position (see Section 5-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11).
Check for proper input power connections (see Section 5-11).
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.
error displayed.
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 5-3).
errors displayed.
Clean and tighten all weld connections.
Wire does not feed.
Check supplementary protector CB1 and reset if necessary.
Check motor control cable connections.
Wire feeds erratically.
Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.
Wire feeds as soon as power is supplied. Check gun trigger. See gun Owner’s Manual.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
Check voltage sense lead connection, clean and tighten if necessary.
Gas does not flow or does not stop flow- Check gas valve and flow meter.
ing; wire feeds.
Wire burns back to gun contact tip when Check to be sure that volt sense lead is connected to the work.
using electrode negative (straight
polarity) process.
OM-272844 Page 40
SECTION 10 − INSIGHT CORE INSTALLATION
7
10-1. License Agreement
You have acquired a device (Insight Core) which includes software licensed by Miller Electric Mfg. Co. Such software products, as well as associated
media, printed materials, and “online” or electronic documentation for such software are protected by international intellectual property laws and
treaties. The software is licensed, not sold. All rights reserved.
10-2. Downloading Connectivity Survey
In order to ensure proper connectivity, visit the Insight Core Download page at https://insight.millerwelds.com/download .
Download and print the Network Connectivity Survey Form.
Ask your corporate IT department to complete the survey.
10-3. Obtaining System IP Address
. The factory default IP address of all Continuum systems is 169.254.0.2.
. Ethernet and WiFi connections each have their own unique IP addresses.
. The power source must be on the same Subnet as the computer used to access the Continuum’s web pages.
1.
Connect your Continuum Welding System per the instructions in the power source Owner’s Manual.
2.
Connect an Ethernet cable between your computer and the power source.
3.
Turn the welding power source on.
4.
From the Feeder (or pendant) main menu screen, go to the Ethernet Settings screen. Using the scroll knob, select System, then Network
Settings, then Ethernet Settings. Note the IP address.
Home
Internet
WiFi
Ethernet
Home > System
System Menu
Program # 1
MIG
.035 Steel ER70
Ar 90 CO2 10
35ST MIG
Setup
Logs
Status
Factory Reset
USB Functions
System Software Revision
Network Settings
System
Home
Back
Home > System > Network > Ethernet
Home > System > Network
Ethernet Settings
Network Menu
Item
MAC
IP Mode
IP Address
Subnet Mask
Network Gateway
DHCP Server
DNS Server
Port
Ethernet Settings
WiFi Settings
Home
System
Value
7C:66:9D:49:30:F3
Dynamic
169.254.0.2
255.255.0.0
10.43.254.250
10.50.10.2
10.50.10.5
80
Back
Home
System
Back
Figure 10-1. Obtaining IP Address
OM-272377 Page 41
10-4. Enabling Insight Core Through The Continuum’s Web Pages
1.
Connect a computer to the welding power source with an Ethernet cable and open a browser.
2.
Enter the system IP address (see Section 10-3) into the address bar. The default IP address is 169.254.0.2.
3.
Press Enter.
Figure 10-2. Connecting To Continuum Web Page
4.
The Continuum system’s web page appears. On the top of the page, click Setup.
Figure 10-3. Continuum Web Page
OM-272377 Page 42
5.
Under Data Connections, click Edit.
Figure 10-4. Setup Page
6.
Enable or disable Insight Core by clicking your selection. After your selection is made, click Save All.
7.
Cycle the machine power by turning the machine off, waiting until the Power On light goes off, and turning power on again.
Figure 10-5. Data Connections Page
OM-272377 Page 43
10-5. Configuring The Network Connection
. If this is the initial installation of a unit, determine what type of installation will be required. Connection information is required for each new installation of the Insight Core product.
. To set up more than one Continuum system, or if a computer near the Continuum is not available, it is more efficient to use the Insight Core Configuration Utility available at the Insight Core Downloads web page: https://insight.millerwelds.com/download .
1.
Connect a computer to the power source with an Ethernet cable and open a browser.
2.
Enter the IP address (see Section 10-3) into the address bar. The default IP address is 169.254.0.2. See Figure 10-2.
3.
Press Enter.
4.
The Continuum system’s web page appears. On the top of the page, click Setup.
S
To configure a WiFi connection using DHCP (dynamic IP addresses), go to Section A.
S
To configure a WiFi connection using static WiFi addressing, go to Section B.
S
To configure a wired Ethernet connection using DHCP (dynamic IP addresses), go to Section C.
S
To configure a wired Ethernet connection using static IP addressing, go to Section D.
A. WiFi Connection Using DHCP (Dynamic Addressing)
1.
On the Setup page, under WiFi Settings, click Edit.
Figure 10-6. Editing WiFi Settings
OM-272377 Page 44
2.
On the screen that appears, under Security Setup, enter your network name (SSID), security type, and security key. This information is found on
the Network Connectivity Survey completed by your IT Department (see Section 10-2).
3.
Click Save Security Settings to save your wireless network settings.
4.
Under WiFi Address, select Dynamic.
5.
Under DNS Address, select DHCP Automatic.
6.
When finished, click Save All.
7.
Cycle the machine power by turning the machine off, waiting until the Power On light goes off, and turning power on again.
Figure 10-7. Configuring WiFi Connection Using DHCP
OM-272377 Page 45
B. WiFi Connection Using Static Addressing
1.
On the Setup page, under WiFi Settings, click Edit (see Figure 10-6).
2.
On the screen that appears, under Security Setup, enter your network name (SSID), security type, and security key. This information is found on
the Network Connectivity Survey completed by your IT Department (see Section 10-2).
3.
Click Save Security Settings to save your wireless network settings.
4.
Under WiFi Address, select Static.
5.
Under Network Information, enter your IP address, subnet mask, and network gateway. This information is found on the Network Connectivity
Survey completed by your IT Department (see Section 10-2).
6.
Under DNS Address, select DNS Server. Enter DNS address from the Network Connectivity Survey completed by your IT Department (see
Section 10-2).
7.
When finished, click Save All.
8.
Cycle the machine power by turning the machine off, waiting until the Power On light goes off, and turning power on again.
Figure 10-8. Configuring WiFi Connection Using Static Addressing
OM-272377 Page 46
C. Wired (Ethernet) Connection Using DHCP (Dynamic Addressing)
1.
On the Setup page, under Ethernet Settings, click Edit.
2.
At the top of the screen that appears, select Dynamic underneath the IP address. The Network Information below will automatically fill in.
3.
Under DNS Address, select DHCP Automatic.
4.
When finished, click Save All.
5.
Cycle the machine power by turning the machine off, waiting until the Power On light goes off, and turning power on again.
Figure 10-9. Configuring Ethernet Connection Using DHCP
Notes
OM-272377 Page 47
D. Wired (Ethernet) Connection Using Static Addressing
1.
On the Setup page, under Ethernet Settings, click Edit.
2.
At the top of the screen that appears, select Static under the IP address.
3.
Under Network Information, enter your IP address, subnet mask, and network gateway. This information is found on the Network Connectivity
Survey completed by your IT Department (see Section 10-2).
4.
Under DNS Address, select DNS Server. Enter DNS address from the Network Connectivity Survey completed by your IT Department (see
Section 10-2).
. Double-check the numbers before saving. A wrong number may be difficult to correct.
5.
When finished, click Save All.
6.
Cycle the machine power by turning the machine off, waiting until the Power On light goes off, and turning power on again.
Figure 10-10. Configuring Ethernet Connection Using Static Addressing
Notes
OM-272377 Page 48
10-6. Verifying Network Connection
. It can take up to five minutes for a WiFi network to connect the first time.
To verify the network connection, reference the feeder (or pendant) display. If a WiFi connection is being used, the box next to WiFi should be yellow. If
an Ethernet connection is being used, the box next to Ethernet should be yellow. Only one (Ethernet or Wifi) is required to establish a network connection. Once the network is identified, the box next to Internet should be green.
1
1
2
3
2
Home
Internet
WiFi
Ethernet
3
Program # 1
MIG
.035 Steel ER70
Ar 90 CO2 10
35ST MIG
Setup
Logs
Status
Internet Connection
Indicator (Green When
Connected)
WiFi Connection Indicator
(Yellow When Connected)
Ethernet Connection
Indicator (Yellow When
Connected)
System
Figure 10-11. Verifying Network Connection
To review settings from the feeder, go to the Ethernet Settings screen. Using the scroll knob, select System, then Network Settings, then either
Ethernet Settings or Wifi Settings.
Home
Internet
WiFi
Home > System
Ethernet
System Menu
Program # 1
MIG
.035 Steel ER70
Ar 90 CO2 10
35ST MIG
Setup
Logs
Status
Factory Reset
USB Functions
System Software Revision
Network Settings
Home
System
Back
Review settings here.
Item
MAC
IP Mode
IP Address
Subnet Mask
Network Gateway
DHCP Server
DNS Server
WiFi Port
Home > System > Network
Network Menu
Ethernet Settings
WiFi Settings
Home
System
Value
7C:66:9D:49:30:F3
static
192.168.1.2
255.255.255.0
192.168.1.2
192.168.1.1
8.8.8.8
80
Back
Home
System
Back
Figure 10-12. Verifying Network Connection
OM-272377 Page 49
10-7. Determining Device Serial Number And License Key
. Obtaining the device serial number and license key is necessary for product registration. Registration will activate your Insight Core account and
give access to all Insight Core data.
1.
Insert a USB drive into the front port on the Continuum Feeder.
1
USB Port
1
Ref. 259 144-A
Figure 10-13. Continuum Feeder USB Location
2.
From the feeder (or pendant) main menu, select System to bring up the System menu. Using the scroll knob, select USB Functions, then Write
to USB, then License Key, then Yes to save the license key and serial number data. This process will load an IP_MAC file onto the USB drive,
which contains the unique license key for your system.
Home
Internet
WiFi
Ethernet
MIG
.035 Steel ER70
Ar 90 CO2 10
35ST MIG
Logs
USB Functions
System Menu
Program # 1
Setup
Home > System > USB
Home > System
Write to System
Write to USB
Factory Reset
USB Functions
System Software Revision
Network Settings
Status
System
Home
Home > System > USB > Write to USB
Home System
Back
Back
Home > System > USB > Write to USB > License
License File
Write to USB Functions
Write License File to USB?
System Settings
License Key
Diagnostic File
No
Yes
Warning: save license file will be lost.
Home
System
Back
Home
System
Figure 10-14. Obtaining Serial Number And License Key
OM-272377 Page 50
Back
3.
4.
Remove the USB drive from the feeder and insert it into your computer. Allow time for the computer to recognize the USB drive.
Find and open the folder named Device License Keys on the USB drive.
Figure 10-15. Device License Keys Folder
5.
Open the .txt file called “IP_MAC_ADDR_LIC…” with a text editor (Notepad) to find the module/device serial number and license key needed to
register the device.
Figure 10-16. Device License Key File
6.
Write down or copy and paste the serial number and license key for registration.
Figure 10-17. Device License Key Information
. This file also verifies the connections information. Exact information in the file will vary based on connection type and device.
. To continue device registration, proceed to Section 10-8.
OM-272377 Page 51
10-8. Registering Initial Device And Creating An Account
1.
Open a web browser and navigate to https://insight.millerwelds.com/registration .
2.
Fill in all information shown in Figure 10-18. Use serial number and license key from Section 10-7.
. If this device is an additional module to be added to your existing fleet already registered, click Log In button and proceed to Section 10-9.
Serial Number
MC10001Z
AC1000000X1X1X00XX00X0XX
License Key
From Step #2
Figure 10-18. Registering A New Account
3.
After clicking on the Register button, the homepage for the company that was just created will appear (see Figure 10-19).
Figure 10-19. Insight Core Company Dashboard
. To register additional devices proceed to Section 10-9.
OM-272377 Page 52
10-9. Registering Additional Devices
1.
Log in to Insight Core website at https://insight.millerwelds.com/ .
2.
Click on the Configuration tab (See Figure 10-20).
3.
On the Configuration tab, click on the Register New Device button.
Figure 10-20. Configuration Screen
4.
Enter the information for the new device you intend to register.
5.
A confirmation screen will appear. If the information is correct, click on the Save button (see Figure 10-21).
MC10001Z
AC1000000X1X1X00XX00X0XX
Figure 10-21. Register Device Confirmation Screen
6.
After registration, the device will appear inside the corporate asset tree and begin displaying activity as operators begin welding with this power
source.
OM-272377 Page 53
SECTION 11 − ELECTRICAL DIAGRAMS
Figure 11-1. Circuit Diagram For Contiuum 350 Model (Page 1 of 2)
OM-272844 Page 54
272 802-A
OM-272844 Page 55
Figure 11-2. Circuit Diagram For Continuum 350 Model (Page 2 of 2)
OM-272844 Page 56
272 802-A
OM-272844 Page 57
Figure 11-3. Circuit Diagram For Contiuum 500 Model (Page 1 of 2)
OM-272844 Page 58
272 800-A
OM-272844 Page 59
Figure 11-4. Circuit Diagram For Continuum 500 Model (Page 2 of 2)
OM-272844 Page 60
272 800-A
OM-272844 Page 61
SECTION 12 − PARTS LIST FOR 350 AND 500 MODELS
4
22
5 Figure 12-7
2
19
11 Figure 12-6
12
18
21
13 Figure 12-2
14 Figure 12-3
15
7 Figure 12-4
18
17
6
3
9
16
1
20
10
8
Figure 12-5
275 982-A
Figure 12-1. Main Assembly
OM-272844 Page 62
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
500
350
Figure 12-1. Main Assembly
Model Model
. . 1 . . . . . . . . . . . . . +265236 . . Base ,Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 219844 . . . . Label, Warning Electric Shock/Exploding Parts−Wdles . . . . . . 1 . . . . . 1
. . 2 . . . . . . . . . . . . . +265245 . . Panel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 179310 . . . . Label, Warning General Precautionary Wordless Intl Small . . 1 . . . . . 1
. . 3 . . . . . . . . . . . . . +265246 . . Panel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 179310 . . . . Label, Warning General Precautionary Wordless Intl Small . . 1 . . . . . 1
. . 4 . . . . . . . . . . . . . +265240 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 272842 . . . . Label, Warning Falling Equipment Can Injure−Wordles . . . . . . 1 . . . . . 1
. . 5 . . . . . . . . . . Figure 12-7 . . Rear Panel Assy, Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 267903 . . Output Terminal Assy, (See Figure 12-5) . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 7 . . . . . . . . . . Figure 12-4 . . Fan Panel Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 8 . . . . . . . . . . Figure 12-5 . . Front Panel Assy, Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 9 . . . . . . . . . . . . . . 269472 . . Gasket, Sealing 17.000L x .250w x .063t . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 10 . . . . . . . . . . Figure 12-5 . . Front Panel Assy, Lower Continuum . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . Figure 12-6 . . Penthouse Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 12 . . . . . . . . . . . . . . 270511 . . Insulator,.010 Thick X 4.500 X 8.000 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 13 . . . . . . . . . . Figure 12-2 . . Windtunnel, Rh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 14 . . . . . . . . . . Figure 12-3 . . Windtunnel, Lh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 15 . . . . PC1 . . . . 248915 . . Circuit Card Assy, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 16 . . . . PC4 . . . . 273420 . . Circuit Card Assy, Inverter - Arc Control W/Prog . . . . . . . . . . . . . 1 . . . . . 1
. . 17 . . . . PC13 . . . . 275213 . . Circuit Card Assy, Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 275235 . . . . Fuse, Crtg 3 Amp 1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 18 . . . . . . . . . . . . . . 266420 . . Plate, Lift Eye Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 19 . . . . . . . . . . . . . . 273656 . . Bracket, Support Emc Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 20 . . . . . . . . . . . . . . 267407 . . Plate, Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 21 . . . . . . . . . . . . . . 272415 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 22 . . . . . . . . . . . . . . 274551 . . Bracket, Guard Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 274563 . . Kit, Strain Relief 1.250 (Including) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 255675 . . . . Bushing, Strain Relief .865/1.26 Id x 1.250 Mtg Hole . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 274562 . . . . Nut, Conduit 1.250-11.5 Npt Pld . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-272844 Page 63
. Hardware is common and
not available unless listed.
4
6
7
14
21
1
13
16
18
3
19
17
15
20
5
2
8
9
12
10
11
Ref. 269 780-D
Figure 12-2. Right-Hand Windtunnel w/Components
Item
No.
Dia.
Mkgs.
.. 1 ..............
. . 2 . . . . T1-T2 . . .
. . 2 . . . . . T1 . . . . .
...................
...................
.. 3 ..............
.. 4 ..............
.. 5 ..............
.. 6 ..............
. . 7 . . . D1−D4 . . .
.. 8 ..............
.. 9 ..............
. . 10 . . . . . . . . . . . . . .
. . 11 . . . . . . . . . . . . . .
. . 12 . . . . . . . . . . . . . .
. . 13 . . . . . . . . . . . . . .
. . 14 . . . . . L5 . . . . .
. . 15 . . . . . . . . . . . . . .
. . 16 . . . . . . . . . . . . . .
. . 17 . . . . . C3 . . . . .
. . 18 . . . . VR1 . . . .
. . 19 . . . . . C5 . . . . .
. . 20 . . . . . . . . . . . . . .
. . 21 . . . . . . . . . . . . . .
Part
No.
265243
252442
267776
263299
267924
213029
199840
272416
233052
201531
196355
025248
236727
179276
253547
245520
273683
223343
267438
138695
269178
265285
057360
267870
Description
Figure 12-2. Right-Hand Windtunnel
w/Components (Figure 12-1, Item 13)
Quantity
500
350
Model Model
. . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Xfmr, Hf Litz (500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Xfmr, Hf Litz (350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Heat Sink Assy, Output Diode (500)(Includes Items 3-7) . . . . . .
. . Heat Sink Assy, Output Diode (350)(Includes Items 3-7) . . . . . .
. . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 26.00in Lead . . . . .
. . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand-off, Insul .250-20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . .
. . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Snap-in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . .
. . Bus Bar, Xfmr Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . .
. . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clip, Wire Stdf .40-.50 Bndl .156hole .031-.078thk . . . . . . . . . . .
. . Plate, Blank Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor, Cer Disc .01 uF 1000 Vdc w/Terms . . . . . . . . . . . . . . .
. . Varistor, w/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor,Polyp Met Film 30. Uf 550 Vdc . . . . . . . . . . . . . . . . . . .
. . Blank, Snap-In Nyl 1.375 Mtg Hole Black . . . . . . . . . . . . . . . . . . .
. . Plate, Mtg Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
0
1
0
1
1
2
1
1
2
4
2
1
2
1
1
1
2
1
1
1
1
1
1
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
1
2
0
1
0
1
4
1
2
4
4
2
1
2
1
1
1
2
1
1
1
0
0
0
+ 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-272844 Page 64
. Hardware is common and
not available unless listed.
2
7
1
10
9
12
8
3
6
11
3
5
4
269 781-B
Figure 12-3. Left-Hand Windtunnel w/Components
Item
No.
Dia.
Mkgs.
. . 1 . . . . L1-L4 . . . .
.. 2 ..............
. . 3 . . PC2-PC3 . .
. . 3 . . PC2-PC3 . .
.. 4 ..............
.. 5 ..............
.. 6 ..............
.. 7 ..............
.. 8 ..............
.. 9 ..............
. . 10 . . . . . . . . . . . . . .
. . 11 . . . . . . . . . . . . . .
. . 12 . . . . . . . . . . . . . .
...................
...................
...................
...................
Part
No.
252375
265242
248920
265947
259517
259515
252449
173632
262497
153403
266939
266940
184260
269968
276359
047838
267386
Description
Figure 12-3. Left-Hand Windtunnel
w/Components (Figure 12-1, Item 14)
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
500
350
Model Model
Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Capacitor (500) . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Capacitor (350) . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Transistor IGBT Module (Inverter) . . . . . . . . . . . . . . . . . . . . . .
Kit, Transistor IGBT Module (Boost) . . . . . . . . . . . . . . . . . . . . . . .
Thermistor, Ntc 30k Ohm @ 25 Deg C 8.00in Lead . . . . . . .
Thermistor, Ntc 30k Ohm @ 25 Deg C 12.00in Lead . . . . . . .
Stand-off Support, PC Card .156 Dia W/P&L 1.125 . . . . . . . . . .
Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . .
Heat Sink, Igbt Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Sink, Igbt Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Core, Ferrite 31.60mm Od X 19.55mm Id . . . . . . . . . . . . . . . . . . .
Core, Ferrite 14.30mm Od X 6.35mm Id . . . . . . . . . . . . . . . . . . . .
Blank, Snap-In Nyl 1.000 Mtg Hole Black . . . . . . . . . . . . . . . . . . .
Plate, Input Inductor Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
0
2
2
2
1
1
1
4
1
1
1
1
1
2
1
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
4
1
2
0
4
4
1
1
1
6
1
1
1
1
1
0
0
+ 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-272844 Page 65
. Hardware is common and
not available unless listed.
4
4
5
1
3
5
4
2
269 782-B
Figure 12-4. Fan Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Fan Panel Assembly (Figure 12-1, Item 7)
. . 1 . . . . . . . . . . . . . . 265241 . . Panel, Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . FM1-FM2 . . 213072 . . Fan, Muffin 115v 60hz 3400 Rpm 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 2
. . 3 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 3
. . 5 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . . 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-272844 Page 66
. Hardware is common and
not available unless listed.
2
3
4
5
1
7
18
17
11
16
12
8
22
14 9
13
20
19
21
10
15
6
269 783-A
Figure 12-5. Front Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Quantity
Description
Figure 12-5. Front Panel Assembly (Figure 12-1, Items 6, 8 and 10)
. . 1 . . . . . . . . . . . . . . 252825 . . Bezel, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 2 . . . . . . . . . . . . . . 253548 . . Panel, Top Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . . 256859 . . Circuit Card Assy, Led . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 4 . . . . . . . . . . . . . . 261870 . . Cover, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 5 . . . . . . . . . . . . . . 252445 . . Switch, Rotary On/Off 3PH 20Amp 600V 2 Layer . . . . . . . . . . . . . . . . . . . .
. . 6 . . . . . . . . . . . . . . 265467 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 7 . . . . . . . . . . . . . . 252821 . . Enclosure, Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 8 . . . . . . . . . . . . . . 262325 . . Panel, Front Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 9 . . . . . . . . . . . . . . 265239 . . Panel, Output Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 269800 . . . Terminal Pwr Assy, Front (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 10 . . . . . . . . . . . . . . 250037 . . . . Insulator, Bulkhead Front .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 11 . . . . . . . . . . . . . . 250039 . . . . Insulator, Bulkhead Rear .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 12 . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 13 . . . . . . . . . . . . . . 186228 . . . . O-ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 14 . . . . . . . . . . . . . . 185718 . . . . O-ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 15 . . . . . . . . . . . . . . 252830 . . . . Terminal, Pwr Output Front Bolted Rear Int Thread . . . . . . . . . . . . . . . . .
. . 16 . . . . . . . . . . . . . . 185714 . . . . Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern . . . . . . . . . . . .
. . 17 . . . . . . . . . . . . . . 185717 . . . . Nut, M20-1.5 1.00hex .19h Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 18 . . . . . . . . . . . . . . 229333 . . . . Screw, M10-1.5x 20 Hex Hd-pln 8.8 Pld Sems . . . . . . . . . . . . . . . . . . . .
. . 19 . . . . . . . . . . . . . . 256961 . . Lead List, Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 20 . . . . . C4 . . . . . 138695 . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . VR2 . . . . 269178 . . . Varistor, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 22 . . . . . . . . . . . . . . 057359 . . Blank, Snap-in Nyl .375 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate Continuum (Order By Model & Serial No.) . . . . . . . . . .
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-272844 Page 67
. Hardware is common and
not available unless listed.
2
11
9
7
4
10
6
5
8
12
3
1
275 951-A
Figure 12-6. Penthouse Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-6. Penthouse Assembly (Figure 12-1, Item 11)
. . 1 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 7
. . 2 . . . . . W1 . . . . . 180270 . . Contactor, Def Prp 40a 3p 24vac Coil W/Boxlug . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . +265238 . . Panel, Upper Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 155436 . . . . Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 136076 . . Resistor, Ww Fxd 30 W 200 Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . +265261 . . Lift Eye, Formed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 272843 . . . . Label, Warning Input Connections/Elec Shck Wrdless . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 273338 . . . . Label,Warning Hot Surfaces (Wordless) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 266232 . . Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 256975 . . Seal, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . PC19 . . . . 273411 . . Assy, Communication Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 262090 . . Feeder Power Board Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PC14 . . . . 275221 . . . . Circuit Card Assy, Control Feeder Power Pri . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 275235 . . . . . . Fuse, Crtg 3 Amp 1000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 262089 . . . . Bracket, Feeder Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 276629 . . Bracket, Mtg Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 271847 . . Block, Term 115 Amp 1 Pole Screw Term 2−14 Wire . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 272886 . . Filter,Input 3 Phase 34 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 276356 . . . Core, Ferrite 25.90mm Od X 12.80mm Id . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 269968 . . . Core, Ferrite 31.60mm Od X 19.55mm Id . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 276360 . . . Core, Ferrite 9.50mm Od X 4.75mm Id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-272844 Page 68
. Hardware is common and
not available unless listed.
19
1
20
15
18
16
14
10
21
11
8
9
17
12
5
6
7
4
13
3
2
Ref. 269785-E
Item
No.
Dia.
Mkgs.
Part
No.
Figure 12-7. Rear Panel Assembly
Description
Quantity
Figure 12-7. Rear Panel Assembly (Figure 12-1, Item 5)
. . 1 . . . . . . . . . . . . . +272308 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 194557 . . . . Label, Warning Electric Shock Can Kill Etc Wordless . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate Rear (Order By Model And Serial Number) . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 268891 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 264114 . . Boot, Positive Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 269799 . . Terminal Pwr Assy, Output (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 260223 . . . . Terminal, Pwr Output Tabbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 186228 . . . . O-ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 250037 . . . . Insulator, Bulkhead Front .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 185718 . . . . O-ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 250039 . . . . Insulator, Bulkhead Rear .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 185714 . . . . Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 185717 . . . . Nut, M20-1.5 1.00hex .19h Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . . . . . . . . . . . 257290 . . Panel, Rear Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 263536 . . Rail, Din 35mm X 7.5mm X 1.969in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . PC16 . . . . 261838 . . Circuit Card Assy, Power Source 10 Pin Filter . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . CB1 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 269208 . . Plugs, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 260822 . . Antenna,Rf Monopole 2.4ghz Screw Mount . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . . . 184946 . . Blank, Snap−In Nyl .625 Mtg Hole Black D/D . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . . . 275563 . . Cable Assy, Rj45 Male/M12 Female .4m Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 275313 . . Panel, Rear Enet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 269416 . . . . Label,Ethernet/Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . 271543 . . Cable Assy,Rf Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-272844 Page 69
Notes
Notes
Notes
Effective January 1, 2017
(Equipment with a serial number preface of MH 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 date of
6.
90
Days — Parts
this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
* Canvas Covers
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
* Induction Heating Coils and Blankets, Cables, and
FITNESS.
Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any
* M-Guns
warranted parts or components that fail due to such defects in material
* MIG Guns, Subarc (SAW) Torches, and External
or workmanship. Miller must be notified in writing within thirty (30) days
Cladding Heads
of such defect or failure, at which time Miller will provide instructions on
*
Remote
Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted
* Replacement Parts (No labor)
as an online warranty claim, the claim must include a detailed
* Spoolmate Spoolguns
description of the fault and the troubleshooting steps taken to identify
failed components and the 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
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* 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.)
* 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
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* 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 2017-01
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
© 2017 Miller Electric Mfg. Co.
2017−01
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