Miller | MK270536C | Owner Manual | Miller DIMENSION 650 User manual

Miller DIMENSION 650 User manual
OM-263655K
2019−05
Processes
Multiprocess Welding
Description
Arc Welding Power Source
t
Dimension 650
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: MULTIPROCESS
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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 2017−06
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
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. Features And Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Static Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Removing Right Side Panel and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Selecting Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Optional Low Open Circuit Voltage (OCV) Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Alternate Configuration Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − GTAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Typical Connection For GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. GTAW - TIG Remote Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. GTAW - Lift-Arc TIG Output-On Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
9
9
10
10
10
10
10
10
11
11
12
12
13
13
14
15
16
16
17
17
18
18
20
22
22
23
23
24
25
25
26
27
TABLE OF CONTENTS
SECTION 8 − GMAW/FCAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . .
8-2. GMAW/FCAW - Remote Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . .
8-4. GMAW/FCAW - (Gas) Output-On Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. FCAW-S (No Gas) Output-On Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − SMAW/CAC-A OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Typical Connection For SMAW And CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. SMAW - Stick Remote Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. SMAW - Stick Output-On Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. CAC-A - Gouge Output-On Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − SAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Typical Connection For SAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. SAW - Subarc Remote Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
28
28
29
30
31
32
33
33
34
35
36
37
37
38
39
39
39
40
41
42
44
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2018−01
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 equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
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 weld output in damp, wet, or confined spaces, 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 unit, disconnect input power, and discharge input capacitors according to instructions in Manual 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-263655 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 Ventilate the work 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.
OM-263655 Page 2
D Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
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.
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 proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport 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.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use correct procedures and 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.
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.
MOVING PARTS can injure.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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.
OM-263655 Page 3
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment
perform this installation.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
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.
1-4. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
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 02169 (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 02169 (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 1910.177 Subpart
N, 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-263655 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
som_2018−01_fre
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.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
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 utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
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,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
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).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
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.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
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.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
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.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
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.
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 Éteignez l’unité, débranchez le courant électrique, et déchargez
les condensateurs d’alimentation selon les instructions indiquées
dans le manuel avant de toucher les pièces.
OM-263655 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 auxquelles 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.
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 couper ou souder des jantes ou des roues. Les pneus
peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.
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.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
OM-263655 Page 6
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 Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter 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 Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter 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.
OM-263655 Page 7
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 Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
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 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.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
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 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
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
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 02169 (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 Spec-
trum 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 02169 (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 1910.177 Subpart N,
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-263655 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
When power is applied failed parts can explode or cause other parts to explode.
Safe89 2012−07
3-2. Miscellaneous Symbols And Definitions
A
V
Amperage
Gas Tungsten Arc
Welding (GTAW)
Voltage
Variable
Inductance
On
X
%
Duty Cycle
Percent
Three Phase
Off
Arc Force
Direct Current
(DC)
Input Voltage
Positive
Output
Negative
Three Phase
Static Frequency
ConverterTransformerRectifier
Remote
Gas Metal Arc
Welding (GMAW)
Flux Cored Arc
Welding (FCAW)
Air Carbon Arc
Cutting (CAC-A)
Shielded Metal
Arc Welding
(SMAW)
Lift-Arc Operation
(GTAW)
Submerged Arc
Welding (SAW)
U2
I2
U1
Hz
I1eff
U0
Conventional
Load Voltage
Rated Welding
Current
S
I1max
IP
Suitable For
Welding In An
Environment With
Increased Risk Of
Electric Shock
Rated Maximum
Supply Current
Degree Of
Protection
Line Connection
Alternating
Current (AC)
Primary Voltage
Protective Earth
(Ground)
Hertz
Frame or Chassis
Maximum Effective Supply Current
Circuit Breaker
Rated No Load
Voltage (OCV)
OM-263655 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Features And Benefits
LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input power fluctuation.
Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments.
Fan-On-Demandt cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through the machine.
Thermal Overload Protection automatically shuts down the unit, only when necessary to prevent damage to internal components if the duty cycle
is exceeded or air flow and cooling are restricted (see Section 4-8).
Auto Remote Sense enables the unit to automatically sense the connection of a remote control. Operation of the remote control is dependent on the
Mode Switch Setting (see Section 6-2).
Lift-Arct TIG starts provide a contamination free weld without the use of high frequency (see Section 7-3).
Adaptive Hot Startt for Stick increases the output amperage at the start of a weld to eliminate electrode sticking (see Sections 9-2 and 9-3).
4-2. Arc Controls
Arc Control in Stick Modes allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes (see Section 9-2).
Arc Control in Wire Modes influences the arc stiffness, bead width and appearance, and puddle fluidity (see Sections 8-2 and 8-3).
4-3. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
4-4. Software Licensing Agreement
The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at
https://www.millerwelds.com/eula and are incorporated by reference herein.
4-5. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-9 and 5-10 for information on connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
A. Input Voltage And Current At Rated Output
Amperes Input At
Rated Output
Output Ratings
Process
GTAW (Lift-Arc TIG)
GTAW (TIG)
SMAW (Stick)
GMAW/FCAW (Gas)
FCAW-S (No Gas)
SAW (Subarc)
CAC-A (Gouge)
Current
(Amperes)
Voltage
(DC)
Duty Cycle
(%)
380 VAC
(50 Hz)
460 VAC
(60 Hz)
KW
KVA
650
34
100
39.6
34.9
24.4
27.8
750
34
60
45.8
39.2
28.2
31.3
815
34
25
50.0
42.5
30.7
33.9
650
44
100
50.3
43.1
31.0
34.4
750
44
60
58.2
49.4
35.9
39.4
650
44
100
50.3
43.1
31.0
34.4
750
44
60
58.2
49.4
35.9
39.4
815
44
25
63.4
53.8
39.1
42.8
1.02
0.28
0.057
0.22
1.11
0.37
0.142
0.30
Idle (Fan Off)
Idle (Fan On)
OM-263655 Page 10
Input Power
(460V 60 Hz Three Phase)
N/A
B. Output Range
Process
Output Range
Rated No-Load Voltage (Uo)
380 VAC
460 VAC
GTAW (Lift-Arc TIG)
Output On
10A−815A
12V
12V
GTAW (TIG)
Remote
10A−815A
61V
72V
SMAW (Stick)
Remote
30A−815A
65V
79V
Output On
30A−815A
65V*
79V*
CAC-A (Gouge)
Output On
30A−815A
65V*
79V*
GMAW/FCAW (Gas)
Remote
10V−44V
65V
79V
Output On
10V−44V
65V
79V
FCAW-S (No Gas)
Output On
10V−44V
65V
79V
SAW (Subarc)
Remote
10V−65V
65V
79V
*Unit can be configured to reduce Rated No-Load Voltage - Ur. See Section 6-3 for more information.
4-6. Dimensions And Weight
Hole Layout Dimensions
28-3/16 in.
(716 mm)
A
14-1/4 in. (362 mm)
B
30-1/4 in. (768 mm)
24-3/16 in.
(614 mm)
B
C
11/16 in. (17 mm)
Weight
C
A
158 lb (71.7 kg)
16-11/16 in.
(406 mm)
31-5/8 in.
(803 mm)
269320-A
269319-A
4-7. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use.
IP23 2017−02
B. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
14 to 104°F (−10 to 40°C)
−4 to 131°F (−20 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Temp1_016- 08
OM-263655 Page 11
4-8. Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
700
If unit overheats, output stops, error
message is displayed (see Section
11-3), and cooling fan runs. Wait for
unit to cool and error message to
clear. Reduce amperage or duty
cycle before welding.
600
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
900
OUTPUT AMPERES
800
500
400
300
200
100
0
10
20
30
40
% DUTY CYCLE
50
60 70 80 90100
100% Duty Cycle At 650 Amperes
Continuous Welding
60% Duty Cycle At 750 Amperes
6 Minutes Welding
4 Minutes Resting
25% Duty Cycle At 815 Amperes
2 1/2 Minutes Welding
7 1/2 Minutes Resting
Overheating
A/V
OR
Reduce Duty Cycle
duty1 4/95 − SA-181560 / 263638-A
4-9. Static Output Characteristics
The static (output) characteristics of the welding power source can be described as flat during the GMAW, FCAW and SAW processes and drooping
during the SMAW, CAC−A and GTAW processes. Static characteristics are also affected by control settings (including software), electrode, shielding
gas, weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welding power source.
OM-263655 Page 12
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
!
Do not move or operate unit
where it could tip.
1
OR
2
Location And Airflow
3
18 in.
(460 mm)
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
loc_large 2015-04
Notes
OM-263655 Page 13
5-2. Removing Right Side Panel and Measuring Input Capacitor Voltage
8
!
Turn Off welding power
source, and disconnect input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
1
Right Side Panel
Typical Bleeder Resistor
25 to 1000 ohm,
5 watt resistor
To remove panel, remove screws
securing panel to unit.
#16 AWG 1000 volts DC
insulation rating, approx.
3 in. (76 mm) leads
1
2
Interconnect Board PC2
3
Voltmeter
Measure the DC voltage across the
screw terminals on PC2 as shown
until voltage drops to near 0 (zero)
volts.
4
5
6
7
PM1−C1
PM1−E2
PM3−C1
PM3−E2
. If the capacitor voltage does
3
2
4
not drop to near zero after several minutes, use a bleeder resistor of between 25 and 1000
ohms, at least 5 watts, #16
AWG 1000 volts DC insulating
rating wire to discharge the capacitor(s) . Connect bleeder resistor from C1 to E2 on PM1
and PM3 until capacitor voltage
decreases to zero.
5
8
Typical Bleeder Resistor
An example of a typical bleeder resistor is shown on this page.
Red Lead
Proceed with job inside unit. Reinstall right side panel when finished.
3
Lift Eye Strap
Removed For
Clarity
Red Lead
6
7
Tools Needed:
3/8 in.
OM-263655 Page 14
Ref. 269061-C / 269319-B / 263633-B
5-3. Selecting Input Voltage
!
Turn Off welding power
source, disconnect input
power, and check voltage
on input capacitors according to Section 5-2 before
proceeding.
Check input voltage available at
site.
Check voltage selected in unit.
Changing selection is only necessary if selected value does not
match input voltage.
1
2
3
Interconnect Board PC2
Receptacle RC7 (Connection
For 460 VAC Input Power)
Receptacle RC6 (Connection
For 380 VAC Input Power)
To change voltage selection, move
relinking plug PLG7 on PC2 to
match input power voltage.
Lift Eye Strap
Removed For
Clarity
1
2
460
VAC
Link
3
380
VAC
Link
Tools Needed:
3/8 in.
269061-C
OM-263655 Page 15
5-4. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
AWG (mm2)
300 ft
(90 m)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x3/0 (3x95)
600
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
700
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
800
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
4x4/0 (4x120)
900
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08
5-5. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
. See Section 5-6 for information on
connecting to weld output terminals, and Sections 7-1 thru 10-1 for
standard connection diagrams.
1
2
output term1 2015−02
OM-263655 Page 16
5-6. Connecting Weld Output Cables
1
2
3
5
4
5
Tools Needed:
3/4 in. (19 mm)
!
!
!
269322-A
Turn off power before connecting to
weld output terminals.
1
Weld Output Terminal
2
Supplied Weld Output Terminal Nut
nals to weld output terminal with nut and
bolt as shown, so that weld cable terminal
is tight against copper bar. Do not place
anything between weld cable terminal
and copper bar. Make sure that the surfaces of the weld cable terminal and
copper bar are clean.
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
3
Supplied Weld Output Terminal Bolt
4
Copper Bar
5
Weld Cable Terminal
Use correct size weld cables (see
Section 5-4).
Remove supplied Bolt and nut from weld
output terminal. Secure weld cable termi-
5-7. Remote 14 Receptacle Information
A
B
K
Socket*
Socket Information
A
24 volts AC. Protected by supplementary protector CB2.
B
Contact closure to A completes 24 volts AC contactor control circuit.
C
Output to remote control; +10 volts DC.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from remote control.
A/V
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 arc volts.
G
Circuit common for 24 volt AC circuit.
K
Chassis common.
J
I
24 VOLTS AC
H
C L N
M
D
G
E F
Ref. 269319-B
REMOTE
CONTROL
GND
*The remaining sockets are not used.
OM-263655 Page 17
5-8. Supplementary Protector
1
2
3
115 V 20 Amp AC Receptacle
Supplementary Protector CB1
Supplementary Protector CB2
CB1 protects duplex receptacle.
CB2 protects 24 volts AC portion of
Remote 14 receptacle from
overload.
1
Press button to reset supplementary protector.
2
3
Ref 269321-B
5-9. Electrical Service Guide
Elec Serv 2017−01
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Three Phase
Input Voltage (V)
380
460
Rated Maximum Supply Current I1max (A)
64.2
53.8
Maximum Effective Supply Current I1eff (A)
51.0
43.1
Time-Delay Fuses2
80
60
Normal Operating Fuses 3
100
80
6 (16)
8 (10)
214 (65)
200 (61)
8 (10)
8 (10)
Max Recommended Standard Fuse Rating In
Amperes1
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-263655 Page 18
Notes
OM-263655 Page 19
5-10. Connecting Input Power
3
= GND/PE
Earth Ground
9
11
8
L1
5
L2
7
L3
10
1
7
L3 L2 L1
3
6
4
Tools Needed:
2
1
3/8 in.
5/32 in.
5
Ref. Input5 2013−04 / Ref. 803766-C / Ref. 269061-C
OM-263655 Page 20
5-10. Connecting Input Power (Continued)
!
!
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 5-2 before
proceeding.
Installation must meet all National
and Local Codes − have only qualified
persons make this installation.
Disconnect and lockout/tagout input
power before connecting input
conductors from unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
!
Make input power connections to the
welding power source first.
!
Always
connect
green
or
green/yellow conductor to supply
grounding terminal first, and never to
a line terminal.
See rating label on unit and check input voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 5-4. 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 Kit
(Supplied With Machine)
Install strain relief as explained in instructions
supplied with kit.
3
4
5
Contactor W1
Welding Power Source Grounding
Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to machine grounding terminal
first.
6
7
Welding Power Source Line Terminals
Input Conductors L1, L2, L3
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Reinstall side panel on welding power
source.
Disconnect Device Input Power Connections
8
Disconnect Device (switch shown in
the OFF position)
9 Disconnect Device Grounding Terminal
10 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
11 Over-Current Protection
Select type and size of over-current protection using Section 5-9 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
Ref. Input5 2016−06
Notes
OM-263655 Page 21
SECTION 6 − GENERAL OPERATION
6-1. Front Panel
8
2
3
7
4
6
5
110
1
10
9
263561-B / Ref. 269321-B
. Weld
process operation sections describe functionality of the identified items
(See Sections 7-1 thru 9-4).
1
2
3
Remote 14 Receptacle
Left Display
Right Display
OM-263655 Page 22
. The meters display the actual weld output
6
Arc Control
values after arc initiation and remains displayed for approximately three seconds
after the arc is broken.
7
Remote In Use Indicator
8
Mode Switch
4
Adjust Control
9
Weld Output Terminal (−)
5
Power Switch
10 Weld Output Terminal (+)
6-2. Mode Switch Settings
Switch Position
Process
Output Control
Panel Adjust
Remote Adjust
GMAW/FCAW Gas
Output On
Volts
Volts
FCAW−S No-Gas
Output On
Volts
Volts
SMAW Stick
Output On
Amps
No Remote Adjust Panel Only*
CAC−A Gouge
Output On
Amps
No Remote Adjust Panel Only*
GTAW Lift-Arc TIG
Output On
Amps
% Panel Amps
GTAW TIG
Remote 14
Amps
% Panel Amps
SMAW Stick
Remote 14
Amps
% Panel Amps
SAW Subarc
Remote 14
Volts
Volts
GMAW/FCAW Gas
Remote 14
Volts
Volts
*See Section 6-4 For Alternate Configuration Functions.
6-3.
Optional Low Open Circuit Voltage (OCV) Welding Modes
Low OCV Operation
The unit can be optionally configured for low open circuit voltage (OCV) operation in SMAW (Stick) and CAC-A (Gouge) Output-On modes. When
the unit is configured for low OCV operation, a low sensing voltage (approximately 12 VDC) is present between the electrode and the workpiece
prior to the electrode touching the workpiece. Consult a Factory Authorized Agent for information regarding how to configure unit for low OCV
welding operation.
OM-263655 Page 23
6-4. Alternate Configuration Functions
The function of the remote control and panel meters can be changed on this machine.
To view or change the active configuration:
S Place the process selection switch into SMAW (Stick) Output-On mode.
S Quickly tap (press and release) the wire feeder gun trigger or remote output on-off switch 3 to 5 times within a few seconds to view the active
configuration.
S Repeat the tapping sequence to switch to the next configuration. The right meter will briefly display the new configuration before returning to
the preset display.
. Do not turn power off for at least 5 seconds to ensure the new configuration is saved. If supported, Preflow must be disabled on the wire
feeder to recognize gun trigger taps.
Alternate configurations are explained below. See Section 6-2 for default configuration operation.
C 1
SMAW (Stick), CAC-A (Gouge), and SMAW (Stick) Remote:
The right meter displays the preset amperage set with the panel
Adjust Control. When connected, the remote control sets the
percentage of preset amperage. The Remote In Use indicator is
lit while the remote control is connected.
C 2
This is the default configuration as shipped from the factory.
SMAW (Stick) and CAC-A (Gouge): The remote amperage
control is ignored. The Remote In Use indicator is not lit. The
right meter displays the preset amperage.
SMAW (Stick) Remote: The right meter displays the preset amperage set with the panel Adjust Control. When connected, the
remote control sets the percentage of preset amperage. The Remote In Use indicator is lit while the remote control is connected.
C 3
SMAW (Stick) and CAC-A (Gouge): The remote amperage
control is ignored. The Remote In Use indicator is not lit. The
right meter displays the preset amperage.
SMAW (Stick) Remote: The right meter displays the percentage of preset amperage with a remote connected. The remote
control sets the percentage of preset amperage. The Remote
In Use indicator is lit while the remote control is connected.
Turning the panel Adjust Control will briefly display the preset
amperage for 100%.
. Configurations 2 and 3 prevent a wire feeder from affecting the preset amperage of the Stick and Gouge Output-On modes.
OM-263655 Page 24
SECTION 7 − GTAW OPERATION
7-1. Typical Connection For GTAW Process
4
3
1
2
269325-B
6
5
7
8
!
Turn off power before making connections.
1
2
Foot Control
Positive (+) Weld Output Terminal
3
Remote 14 Receptacle
Connect desired remote control to Remote
14 receptacle if required.
4
Gas Cylinder
5
6
7
8
Gas Hose
Negative (−) Weld Output Terminal
TIG Torch
Workpiece
OM-263655 Page 25
7-2. GTAW - TIG Remote Welding Mode
1
2
3
85
263 561-B
!
Weld terminals are energized
through the remote control in
GTAW - TIG Remote welding mode.
1
2
3
Mode Switch
Right Display
Adjust Control
Setup
For typical system connections refer to
Section 7-1.
Rotate Mode Switch to GTAW - TIG Remote position as shown.
The preset amperage is shown in the Right
Display.
Operation
The Adjust Control is used to set desired
preset amperage.
A remote control is required to turn on the
weld output.
. If the remote control has an amperage
adjustment, the adjustment will function as a percentage of the preset amperage. The Remote In Use indicator
will be lit.
. For
best results, gently scratch the
tungsten electrode to the work to initiate an arc. To minimize arc flare at the
end of the weld, pull back the electrode
quickly to extinguish the arc.
OM-263655 Page 26
7-3. GTAW - Lift-Arc TIG Output-On Welding Mode
1
2
12.0
3
4
85
263 561-B
6
“Touch”
1−2
Seconds
5
Do NOT Strike Like A Match!
!
Weld terminals are energized at all
times in GTAW - Lift-Arc TIG Output-On welding mode.
1
2
3
4
5
6
Mode Switch
Left Display
Right Display
Adjust Control
Workpiece
Tungsten Electrode
Setup
For typical system connections refer to
Section 7-1.
Rotate Mode Switch to GTAW - LIFT-ARC
TIG Output-On position as shown.
The open-circuit voltage is shown in the
Left Display. Preset amperage is shown in
the Right Display.
Normal open-circuit voltage is not present
before the electrode touches the workpiece, instead a low sensing voltage is
present. The sensing voltage allows the
electrode to touch the workpiece without
overheating, sticking, or getting contaminated.
Operation
The Adjust Control is used to set desired
preset amperage.
. If a remote control is used for amper-
age adjustment, the adjustment will
function as a percentage of the preset
amperage. The Remote In Use indicator will be lit.
. For best results, firmly touch the tung-
sten electrode to the workpiece at the
weld start point. Hold electrode to
workpiece for 1-2 seconds, and lift
electrode. An arc will form when the
electrode is lifted. To minimize arc flare
at the end of the weld, pull back the
electrode quickly to extinguish the arc.
OM-263655 Page 27
SECTION 8 − GMAW/FCAW OPERATION
8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process
9
1
2
3
8
7
4
269323-B
6
5
!
Turn off power before making
connections.
5
Workpiece
6
Gun
7
Wire Feeder
1
Remote 14-Receptacle
2
Positive (+) Weld Output Terminal
3
Negative (−) Weld Output Terminal
8
Gas Hose
4
Ground Cable to Workpiece
9
Gas Cylinder
OM-263655 Page 28
Use of shielding gas is dependant on Wire
Type.
. The
connection diagram illustrates
DCEP (reverse polarity) suitable for all
wires except self-shielded FCAW. The
majority of self-shielded FCAW wires
require DCEN (straight polarity).
8-2. GMAW/FCAW - Remote Welding Mode
1
2
3
4
25.0
263 561-B
!
1
2
3
4
Weld terminals are energized
through the remote control in
GMAW/FCAW Remote welding
mode.
Mode Switch
Left Display
Adjust Control
Arc Control
Setup
For typical system connections refer to
Section 8-1.
Rotate Mode Switch to GMAW/FCAW
Remote position as shown.
The preset voltage is shown in the Left Display.
Operation
The Adjust Control is used to set desired
preset voltage.
. The preset voltage can be adjusted re-
motely at the wire feeder if the feeder
has a voltage control. This voltage con-
trol will override the Adjust Control of
preset voltage on the welding power
source. The Remote In Use indicator
will be lit.
Arc Control
Arc control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and wires. The star setting is
good for most applications. Use soft settings (0−25) to soften the arc and increase
puddle fluidity. Use stiff settings (0−25) to
stiffen the arc and reduce puddle fluidity.
OM-263655 Page 29
8-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process
10
1
9
2
4
8
3
7
5
6
269324-B
!
Turn off power before making connections.
1
2
3
4
5
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
Ground Cable to Workpiece
Workpiece
Voltage Sensing Clamp
OM-263655 Page 30
6
Gun
7
Gun Trigger Receptacle
8
Wire Feeder
9
Gas Hose
10 Gas Cylinder
Use of shielding gas is dependant on Wire
Type.
. The
connection diagram illustrates
DCEP (reverse polarity) suitable for all
wires except self-shielded FCAW. The
majority of self-shielded FCAW wires
require DCEN (straight polarity).
8-4. GMAW/FCAW - (Gas) Output-On Welding Mode
1
2
3
4
25.0
263 561-B
!
Setup
Weld terminals are energized at all
times in GMAW/FCAW (Gas) Output-On welding mode.
For typical system setup connections refer
to Section 8-3.
1
Mode Switch
Rotate Mode Switch to GMAW/FCAW
(Gas) Output-On position as shown.
2
Left Display
The Left Display toggles between open circuit voltage and preset voltage.
3
Adjust Control
Operation
4
Arc Control
The Adjust Control is used to set desired
preset voltage.
. The Left Display toggling momentarily
pauses while the preset voltage is adjusted.
Arc Control
Arc control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and wires. The star setting is
good for most applications. Use soft settings (0−25) to soften the arc and increase
puddle fluidity. Use stiff settings (0−25) to
stiffen the arc and reduce puddle fluidity.
OM-263655 Page 31
8-5. FCAW-S (No Gas) Output-On Welding Mode
2
1
3
4
25.0
263 561-B
!
Setup
Weld terminals are energized at all
times in FCAW-S (No Gas) Output-On welding mode.
For typical system setup connections refer
to Section 8-3.
1
Mode Switch
Rotate Mode Switch to FCAW-S (No Gas)
Output-On position as shown.
2
Left Display
The Left Display toggles between open circuit voltage and preset voltage.
3
Adjust Control
Operation
4
Arc Control
The Adjust Control is used to set desired
preset voltage.
OM-263655 Page 32
. The Left Display toggling momentarily
pauses while the preset voltage is adjusted.
Arc Control
Arc control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and wires. The star setting is
good for most applications. Use soft settings (0−25) to soften the arc and increase
puddle fluidity. Use stiff settings (0−25) to
stiffen the arc and reduce puddle fluidity.
SECTION 9 − SMAW/CAC-A OPERATION
9-1. Typical Connection For SMAW And CAC-A Process
5
4
3
269326-B
2
1
6
7
!
Turn off power before making connections.
cutting torch to positive weld output terminal.
Connect desired remote control to remote
14 receptacle as required.
1
Electrode Holder
(Carbon Arc)
2
3
4
5
6
7
For CAC-A process connect carbon arc
Electrode Holder
Positive (+) Weld Output Terminal
Remote 14 Receptacle
Compressed Air LIne
Negative (−) Weld Output Terminal
Workpiece
OM-263655 Page 33
9-2. SMAW - Stick Remote Welding Mode
1
2
3
4
85
263 561-B
!
Weld terminals are energized
through the remote control in
SMAW - Stick Remote welding
mode.
1
Mode Switch
2
Right Display
3
Adjust Control
4
Arc Control
Setup
For typical system connections refer to
Section 9-1.
Rotate Mode Switch to SMAW - Stick Remote position as shown.
The preset amperage is shown in the Right
Display with the Amps Indicator lit.
OM-263655 Page 34
Operation
The Adjust Control is used to set desired
preset amperage.
A remote control is required to turn on the
weld output.
. If the remote control has an amperage
adjustment, the adjustment will function as a percentage of the preset amperage. The Remote In Use indicator
will be lit.
Adaptive Hot Start automatically increases
welding amperage at the start of a weld.
This helps eliminate electrode sticking during arc initiation.
. For best results at the end of the weld,
pull back the electrode quickly to extinguish the arc.
Arc Control
Arc control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and electrodes. The star setting is good for most applications. Use soft
settings (0 to 25) for smooth running electrodes like E7018. Use stiff settings (0 to
25) for penetrating electrodes like E6010.
9-3. SMAW - Stick Output-On Welding Mode
1
2
84.5
3
4
5
85
263 561-B
!
Weld terminals are energized at all
times in SMAW - Stick Output-On
welding mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
5 Arc Control
Setup
For typical system connections refer to
Section 9-1.
Rotate Mode Switch to SMAW - Stick Output-On position as shown.
The open circuit voltage is shown in the Left
Display and the preset amperage is shown
in the Right Display.
Operation
The Adjust Control is used to set desired
preset amperage.
Adaptive Hot Start automatically increases
welding amperage at the start of a weld.
This helps eliminate electrode sticking during arc initiation.
Arc Control
Arc control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and electrodes. The star setting is good for most applications. Use soft
settings (0 to 25) for smooth running electrodes like E7018. Use stiff settings (0 to
25) for penetrating electrodes like E6010.
. For best results at the end of the weld,
pull back the electrode quickly to extinguish the arc.
OM-263655 Page 35
9-4. CAC-A - Gouge Output-On Mode
1
2
84.5
3
4
350
263 561-B
!
1
2
3
4
Weld terminals are energized at all
times in CAC-A - Gouge Output-On
welding mode.
Mode Switch
Left Display
Right Display
Adjust Control
OM-263655 Page 36
Setup
For typical system connections refer to
Section 9-1.
Rotate Mode Switch to CAC-A - Gouge
Output-On position as shown.
The open circuit voltage is shown in the Left
Display and the preset amperage is shown
in the Right Display.
Operation
The Adjust Control is used to set desired
preset amperage.
SECTION 10 − SAW OPERATION
10-1. Typical Connection For SAW Process
8
Power Source
Back View
7
9
10
5
6
1
Power Source
Front View
3
2
4
269792-A
!
1
2
Turn off power before making connections.
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
3
4
5
6
Ground Cable to Workpiece
Workpiece
Wire Drive Assembly
10 Pin Motor Control Cord
7
8
9
10
Saw Control
Flux System
Flux Valve
14 Pin/115V Y−Cord
OM-263655 Page 37
10-2. SAW - Subarc Remote Welding Mode
1
2
3
25.0
263 561-B
!
1
2
3
Weld terminals are energized
through the remote control in SAW
- Subarc Remote welding mode.
Mode Switch
Left Display
Adjust Control
Setup
For typical system connections refer to
Section 10-1.
OM-263655 Page 38
Welding Power Source
Rotate Mode Switch to SAW - Subarc Remote position as shown.
The preset voltage is shown in the Left Display.
SAW Controller
When using Miller Electric HDC DX controller, select Dimension 652 or SubArc DC
650 for power source selection.
. This product is not compatible with
digital series of subarc equipment.
Operation
Adjust preset voltage remotely at the SAW
controller. This voltage control will override
the Adjust Control of preset voltage on the
welding power source. The Remote In Use
indicator will be lit. See SAW controller
Owner’s Manual for additional information.
SECTION 11 − MAINTENANCE & TROUBLESHOOTING
11-1. Routine Maintenance
!
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Repair Or
Replace
Cracked
Cables
Replace
Damaged Or
Unreadable
Labels
Replace Cracked
Torch Body
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
Blow Out Inside
11-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
269319-B
OM-263655 Page 39
11-3. Help Displays
HELP
1
HELP
6
. All directions are in reference to the front
of the unit. All circuitry referred to is located inside the unit.
Help 1, 6, 7 Display
HELP
7
Indicates a malfunction in the primary power
circuit. If this display is shown, contact a Factory Authorized Service Agent.
HELP
2
Help 2 Display
HELP
3
Help 3 Display
HELP
4
Help 4 Display
5
Help 5 Display
HELP
HELP
HELP
OM-263655 Page 40
8
25
Indicates a malfunction in the thermal protection circuitry. If this display is shown, contact
a Factory Authorized Service Agent.
Indicates the left side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-8). Operation will
continue when the unit has cooled.
Indicates the auxiliary circuit has overheated.
The unit has shut down to allow the fan to cool
it. Operation will continue when the unit has
cooled.
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-8). Operation will
continue when the unit has cooled.
Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. If this display is
shown, contact a Factory Authorized Service
Agent.
Help 25 Display
Indicates machine has reached Duty Cycle
limit (See Section 4-8). Unit must be left on to
power the fan for cooling. Duty Cycle limit will
automatically reset when unit has cooled.
11-4. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-10).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-10).
Check for proper input power connections (see Section 5-10).
No weld output; meter display On.
Input voltage outside acceptable range of variation (see Section 5-9).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-8).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 5-4).
Clean and tighten all weld connections.
Check for correct polarity.
No 24 volts AC output at Remote 14
receptacle.
Reset supplementary protector CB2 (see Section 5-8).
No 115 volts AC output at duplex receptacle.
Reset supplementary protector CB1 (see Section 5-8).
Auxiliary circuit overheated. Allow unit to cool with fan on (see Section 4-8).
Notes
OM-263655 Page 41
SECTION 12 − ELECTRICAL DIAGRAMS
Figure 12-1. Circuit Diagram For Dimension 650 CC/CV 380/460V
OM-263655 Page 42
263636-D
OM-263655 Page 43
SECTION 13 − PARTS LIST
. Hardware is common and
not available unless listed.
14
12
13
15
16
11
17
26
10
24
25
18
23
27
9
22
21
8
29
28
30
20
19
31
6
7
32
39
5
33
34
35
4
36
37
3
38
2
1
269849-F
Figure 13-1. Main Assembly
OM-263655 Page 44
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly
. . 1 . . . . . . . . . . . . . . 267295 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 263624 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . FM1,FM2 . . 213072 . . Fan, Muffin 115V 60Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . See Figure 13-2 . . Panel, Front W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 176226 . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . RC2 . . . . 143976 . . Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . S1 . . . . . 244920 . . Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . See Figure 13-4 . . Windtunnel, Lh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 263647 . . Panel, Side Rh (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 263620 . . . . Panel, Side Folded Edge Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 234534 . . . . Label, Miller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 175256 . . . . Insulator (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 263646 . . Panel, Side Lh (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 263619 . . . . Panel, Side Folded Edge Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 234534 . . . . Label, Miller (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 267339 . . Bracket, Corner Front (Casting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . . . . . . . . . . +263606 . . Cover, Top Folded Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 274964 . . Label, Warning General Precautionary (En/Fr/Sp) . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 274966 . . Label, Warning Falling Equipment (En/Fr/Sp−Sym) . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 232914 . . Seal, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 266958 . . Lift Eye Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 147195 . . Nut, 375−27 .54Hex .25H Nyl Flange .62D . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 . . . . . . . . . . . . . . 154022 . . Cover, Receptacle Duplex GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . . +263598 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 262913 . . Kit, Strain Relief 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 267340 . . Bracket, Hf Lead Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . 214918 . . Rcpt, Str Dx Grd 2P 3W 20A 125V *5−20R . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . . . 265204 . . Ring, Aux Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . CB1 . . . . 093996 . . Supplementary Pro, Man Reset 1P 20A 250 VAC Frict . . . . . . . . . . . . . . . 1
. . 24 . . . . CB2 . . . . 083432 . . Supplementary Pro, Man Reset 1P 10A 250 VAC Frict . . . . . . . . . . . . . . . 1
. . . . . . . . . C17 . . . . 270072 . . Capacitor Assy, W/Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . . . . . W1 . . . . . 180270 . . Contactor, Def Prp 40A 3P 24 VAC Coil W/Boxlug . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . . . W2 . . . . . 255744 . . Relay, Encl 24 VDC Spst 30A/300VAC 4Pin Flange Mtg . . . . . . . . . . . . . . 1
. . 27 . . . . . . . . . . . . . . 272469 . . Bracket, Mounting Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . +263610 . . Cover, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . FM3 . . . . 183918 . . Motor, Fan 24VDC 3000 RPM 43 Cfm W/10 Ohm Resistor . . . . . . . . . . . . 1
. . 30 . . . . . . . . . . . . . . 263623 . . Bracket, Mtg Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . . . 272492 . . Baffle, (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . . . . 272493 . . Baffle, (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . . . . 263597 . . Base, W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . . . . . . . . . . . 264243 . . Bus Bar, Stabilizer/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . . . 269271 . . Insulator, Windtunnel/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . See Figure 13-3 . . Windtunnel, Rh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . . . 272700 . . Label, Warning Electric Shock/Exploding Parts (Sym) . . . . . . . . . . . . . . . . 1
. . 38 . . . . PC2 . . . . 263632 . . Circuit Card Assy, Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . T2 . . . . . 275036 . . XFMR, Control 380/460 VAC Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-263655 Page 45
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (Continued)
. . . . . . . . . PLG1 . . . . 241172 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG3, PLG4 241171 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG5 . . . . 241169 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG7 . . . . 241170 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG2, PLG11
. . . . . . PLG12, PLG13
. . . . . . PLG14, PLG70 131054 . . Housing Rcpt + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . RC11, RC12, RC13
. . . . . . . RC14, RC70 . 135635 . . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . PLG71 . . . 131204 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC71 . . . . 131203 . . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . PLG10, PLG27, PLG28
. . . . . . PLG29, PLG30 241168 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . PLG19 . . . 115094 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC10 . . . . 275039 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-263655 Page 46
. Hardware is common and
1
not available unless listed.
2
15
14
3
4
13
5
6
7
8
12
9
11
10
269850-B
Figure 13-2. Front Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-2. Front Panel
. . 1 . . . . . . . . . . . . . +264279 . . Panel, Front W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 263561 . . Label, Nameplate Miller Dimension 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 231468 . . Nut, 375-32 .56Hex .22H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . . 245663 . . Knob, Encoder 1.250 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 231469 . . Nut, 500-28 .69Hex .28H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 213134 . . Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 174991 . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip-.21 . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 268891 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . . . 264114 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 11 . . . . . . . . . . . . . . 263560 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 263570 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 190512 . . Stand-off, No 6-32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . . 4
. . 14 . . . . . . . . . . . . . . 231470 . . Nut, Adapter Encoder Shaft Mtg 375-32 To 500-28 . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . PC1 . . . . 274999 . . Kit, Circuit Card Assy Front Panel & Display W/Program . . . . . . . . . . . . . . 1
. . . . . . . . PLG56 . . . 241167 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG59, PLG53 241168 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG60 . . . 241169 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG57 . . . 241170 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG55 . . . 241171 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG54 . . . 241172 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG58 . . . 269989 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . C13,C14 . . 267745 . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . VR1, VR2 . . 270076 . . Varistor, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 263611 . . Plug, W/Leads (Voltage Feedback) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 263613 . . Cable Assy, Current Feedback W/Ferrite Core . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 266925 . . Plugs, W/Leads & Current Xfmrs (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . CT1, CT2 . . 266798 . . . . XFMR, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 269893 . . Screw, 500−13x1.00 (Not Shown) Output Stud Hardware . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 222794 . . Nut, 500−13.75 Hex (Not Shown) Output Stud Hardware . . . . . . . . . . . . . 2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-263655 Page 47
. Hardware is common and
not available unless listed.
3
1
4
5
2
6
7
14
8
13
10
9
11
12
269852-C
Figure 13-3. Wind Tunnel, RH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-3. Wind Tunnel, RH
. . 1 . . . . . . . . . . . . . . 263555 . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . RT1 . . . . 199798 . . Thermistor, Ntc 30K Ohm @ 25 Deg C 18.00in 2500V . . . . . . . . . . . . . . . . 1
. . 3 . . . . . Z1 . . . . . 263583 . . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . L1 . . . . . 272366 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 263578 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . . 2
. . 7 . . . . . . . . . . . . . . 170647 . . Bushing, Snap-in Nyl 1.312 id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 145743 . . Lug, Univ W/Scr 600V 2−14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 275090 . . Label, Warning Input Conn/Elec Shock (En/Fr) . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 264199 . . Stand-off, Insul Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 268532 . . Nut, 375-16 .63Hex 1.13H Stl Pld Clr Coupling . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . PM1−PM4 . 263595 . . Kit, Transistor IGBT Module (Vishay) (Contains 2 Modules) . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 273362 . . Plugs, W/Leads (Gate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 14 . . . . SR1 . . . . 184260 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-263655 Page 48
. Hardware is common and
not available unless listed.
13
12
11
9
10
16
1
8
15
18
2
3
4
5
6
7
269851-C
Figure 13-4. Wind Tunnel, LH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-4. Wind Tunnel, LH
. . 1 . . . . . . . . . . . . . +263569 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 245520 . . Bushing, Snap−In Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . 3
. . 3 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109T Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . . 263571 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 5 . . . . HD1 . . . . 168829 . . Transducer, Current 1000A Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 264242 . . Bracket, Mtg Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 263559 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 196355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 9 . . . . . T1 . . . . . 269226 . . Xfmr Assy, Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 263556 . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 R1/C15,R2/C16 266955 . . Resistor/Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . RT2 . . . . 173632 . . Thermistor, Ntc 30K Ohm @ 25 Deg C 12.00in Lead . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 263554 . . Heat Sink, Rect Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . D1−D4 . . . 269909 . . Kit, Diode Power Module (Vishay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 15 . . . . . . . . . . . . . . 199840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 16 . . . . . R3 . . . . . 270758 . . Resistor W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-263655 Page 49
Notes
Effective January 1, 2019
(Equipment with a serial number preface of MK 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.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
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. LLC
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
© 2019 Miller Electric Mfg. LLC
2019−01
Was this manual useful for you? yes no
Thank you for your participation!

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

Download PDF

advertising