Miller | MF120536C | Owner Manual | Miller DIMENSION 650 User manual

Miller DIMENSION 650 User manual
OM-263 655C
2015−02
Processes
Multiprocess Welding
Description
Arc Welding Power Source
t
Dimension 650
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Features And Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. 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. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. 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. TIG Remote Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Lift-Arc TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 8 − GMAW/FCAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . .
8-2. MIG Remote Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . .
8-4. MIG-Gas Output On Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. MIG-No Gas Output On Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − SMAW/CAC-A OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Typical Connection For SMAW And CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Stick Remote Welding Mode - SMAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Stick-Output-On Welding Mode - SMAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Gouge Mode - CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − SAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Typical Connection For SAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Subarc Welding Mode − SAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
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Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
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disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-263 655 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-263 655 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-263 655 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-263 655 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2013−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − 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.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
D
D
D
D
D
D
D
D
D
D
D
D
D
D
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
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.
OM-263 655 Page 5
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les
outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et 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.
OM-263 655 Page 6
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du 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 Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent
de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
LE BRUIT peut endommager l’ouïe.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du
procédé de soudage, les manipuler avec
précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application
spécifique; les maintenir ainsi que les éléments associés en bon
état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur
lors de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
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.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
OM-263 655 Page 7
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
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
D
D
D
D
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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer
des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
OM-263 655 Page 8
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.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D
D
D
D
D
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.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
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).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
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 CEM peuvent créer des interférences
avec certains implants médicaux comme des stimulateurs cardiaques.
Des mesures de protection pour les porteurs d’implants médicaux
doivent être prises: Limiter par exemple tout accès aux passants ou
procéder à une évaluation des risques individuels pour les soudeurs.
Tous les soudeurs doivent appliquer les procédures suivantes pour
minimiser l’exposition aux CEM provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-263 655 Page 9
OM-263 655 Page 10
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe89 2012−07
Notes
OM-263 655 Page 11
3-2. Miscellaneous Symbols And Definitions
A
Amperage
I2
Alternating
Current (AC)
V
Rated Welding
Current
S
Single Phase
Voltage
Increase
On
Circuit Breaker
U0
Hz
Voltage Input
Suitable For
Welding In An
Environment With
Increased Risk Of
Electric Shock
Rated No Load
Voltage (OCV)
Hertz
Pulsed
Scratch Start TIG
Protective Earth
(Ground)
Positive
Line Connection
Three Phase
Static Frequency
ConverterTransformerRectifier
X
%
Duty Cycle
Percent
U1
IP
Three Phase
Lift-Arc Operation
(GTAW)
Air Carbon Arc
Cutting (CAC-A)
Frame or Chassis
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal
Arc Welding
(SMAW)
Submerged Arc
Welding (SAW)
Primary Voltage
Degree Of
Protection
Maximum Effective Supply Current
Voltage Sensing
Feeder
Remote
Variable
Inductance
Negative
Output
Gas Output
Foot Control
Off
Direct Current
(DC)
Constant Current
Gas Metal Arc
Welding (GMAW)
Arc Force
U2
Conventional
Load Voltage
Flux Cored Arc
Welding (FCAW)
Panel
OM-263 655 Page 12
Rated Maximum
Supply Current
Constant Voltage
Lift-Arc Trigger
Hold Operation
(GTAW)
I1eff
I1max
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 4-7).
Auto Remote Sense enables the unit to automatically sense the connection of a remote control. Operation of the remote control is dependent on the
Mode Switch Setting (see Section 6-2).
Lift-Arct TIG starts provide a contamination free weld without the use of high frequency in the Lift-Arc TIG Welding Mode (see Section 7-3).
Adaptive Hot Startt for Stick increases the output amperage at the start of a weld, eliminating electrode sticking in CC and Stick Welding Modes
(see Sections 9-2 and 9-3).
4-2. Arc Controls
DIG control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes in Stick Welding Modes (see Sections
9-2 and 9-3).
Inductance control influences the arc stiffness, bead width and appearance, and puddle fluidity in MIG Welding Modes (see Section 8-2).
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. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-8 and 5-9 for information on connecting input power.
A. Input Voltage And Current 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)
Amperes Input At Rated
Output (50/60 Hz)
Input Power (Three
Phase)
Current
(Amperes)
Voltage
(DC)
Duty Cycle
(%)
380 VAC
460 VAC
KW
KVA
650
34
100
41.2
33.7
24.5
26.9
750
34
60
49.0
40.0
28.6
31.8
815
34
25
53.0
42.1
30.6
33.6
650
44
100
53.2
42.8
30.7
34.0
750
44
60
69.1
49.7
35.8
39.8
650
44
100
53.2
42.8
30.7
34.0
750
44
60
69.1
49.7
35.8
39.8
815
44
25
77.0
54.5
39.1
43.4
0.47
0.40
0.065
0.31
0.56
0.47
0.152
0.41
Idle (Fan Off)
N/A
Idle (Fan On)
B. Output Range
Process
Output Range
Low Open Circuit Voltage (Uo)
Rated No-Load Voltage (Uo) − OCV
GTAW (Lift-Arc TIG)
10A−815A
N/A
12
GTAW (TIG)
10A−815A
12*
SMAW (Stick)
30A−815A
12*
CAC-A (Gouge)
30A−815A
12*
70 (380 VAC)
GMAW/FCAW (Gas)
10V−44V
N/A
80 (460 VAC)
FCAW-S (No Gas)
10V−44V
N/A
SAW (Subarc)
10V−65V
N/A
*See Section 6-3 for more information on Optional Low Open Circuit Voltage Mode.
OM-263 655 Page 13
4-5. Dimensions and Weight
Weight
158 lb (71.7 Kg)
28-3/16 in.
(716 mm)
24-3/16 in.
(614 mm)
30-1/4 in.
(768 mm)
11/16 in.
(17 mm)
16-11/16 in.
(406 mm)
31-5/8 in.
(803 mm)
14-1/4 in.
(362 mm)
269 320-A / / 269 319-A
4-6. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored, but is not intended to be used
for welding outside during precipitation unless sheltered.
IP23 2014−06
OM-263 655 Page 14
4-7. Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
700
If unit overheats, output stops, error
message is displayed (see Section
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-181 560 / 263 638-A
4-8. Static Output Characteristics
The static (output) characteristics of the welding power source can be described as flat during the GMAW and SAW processes and drooping during
the SMAW, CAC−A and GTAW processes. Static characteristics are also affected by control settings (including software), electrode, shielding gas,
weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welding power source.
OM-263 655 Page 15
SECTION 5 − INSTALLATION
5-1. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
3
1
Line Disconnect Device
Locate unit near correct input
power supply.
!
OR
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
2
Tipping
!
Do not move or operate
unit where it could tip.
Location And Airflow
3
18 in.
(460 mm)
18 in.
(460 mm)
269 313-A
OM-263 655 Page 16
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
Red Lead
Typical Bleeder Resistor
An example of a typical bleeder resistor is shown on this page.
Proceed with job inside unit. Reinstall right side panel when finished.
3
Red Lead
Lift Eye Strap
Removed For
Clarity
6
7
Tools Needed:
3/8 in.
Ref. 269 061-B / 269 319-B / 263 633-B
OM-263 655 Page 17
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.
OM-263 655 Page 18
269 061-B
5-4. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged, undersized, or repaired
cables.
100 ft (30 m) or Less
Negative
(−)
* This
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x3/0
(2x95)
2x4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
2x4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
3x3/0
(3x95)
3x3/0
(3x95)
600
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
3x3/0
(3x95)
3x4/0
(3x120)
3x4/0
(3x120)
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)
Welding
Amperes
Positive
(+)
150 ft
(45 m)
10 − 100% Duty Cycle
AWG (mm2)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-K 2013−10
OM-263 655 Page 19
5-5. Connecting Weld Output Cables
1
2
3
5
4
5
Tools Needed:
3/4 in. (19 mm)
!
!
!
269 322-A
Turn off power before connecting to
weld output terminals.
1
Weld Output Terminal
2
Supplied Weld Output Terminal Nut
nals to weld output terminal with nut and
bolt as shown, so that weld cable terminal
is tight against copper bar. Do not place
anything between weld cable terminal
and copper bar. Make sure that the surfaces of the weld cable terminal and
copper bar are clean.
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
3
Supplied Weld Output Terminal Bolt
4
Copper Bar
5
Weld Cable Terminal
Use correct size weld cables (see
Section 5-4).
Remove supplied Bolt and nut from weld
output terminal. Secure weld cable termi-
5-6. Remote 14 Receptacle Information
A
B
K
Socket*
Socket Information
A
24 volts AC. Protected by supplementary protector CB2.
B
Contact closure to A completes 24 volts AC contactor control circuit.
C
Output to remote control; +10 volts DC in MIG
mode. 0 to +10 volts DC in other modes.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from remote control.
A/V
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 arc volts.
G
Circuit common for 24 volt AC circuit.
K
Chassis common.
J
I
24 VOLTS AC
H
C L N
D M
G
E F
Ref. 269 319-A
REMOTE
CONTROL
GND
*The remaining sockets are not used.
OM-263 655 Page 20
5-7. 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 269 321-B
5-8. Electrical Service Guide
Elec Serv 2014−01
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Three Phase
Input Voltage (V)
380
460
Input Amperes (A) At Rated Output
53.6
42.8
90
60
125
80
6
8
203 (62)
200 (61)
6
8
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2
Normal Operating
3
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
4
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-263 655 Page 21
5-9. Connecting Input Power
3
= GND/PE
Earth Ground
9
11
7
L3 L2
8
L1
L1
5
L2
7
L3
10
1
3 6
4
5
2
1
Tools Needed:
3/8 in.
5/32 in.
Input5 2012−05 / Ref. 803 766-C / Ref. 269 061-B
OM-263 655 Page 22
5-9. 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 (Customer Supplied)
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief. Tighten strain relief.
3 Contactor W1
4 Welding Power Source Grounding
Terminal
5 Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to machine grounding terminal
first.
6 Welding Power Source Line Terminals
7 Input Conductors L1, L2, L3
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Reinstall side panel on welding power
source.
Disconnect
Device
Input
Power
Connections
8 Disconnect Device (switch shown in
the OFF position)
9 Disconnect Device Grounding Terminal
10 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
11 Over-Current Protection
Select type and size of over-current protection using Section 5-8 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
Input5 2012−05
Notes
OM-263 655 Page 23
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-263 655 Page 24
. 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
MIG−Gas
GMAW/FCAW
Output On
Volts
Volts
MIG−No Gas
FCAW−S
Output On
Volts
Volts
Stick
SMAW
Output On
Amps
No Remote Adjust Panel Only*
Gouge
CAC−A
Output On
Amps
No Remote Adjust Panel Only*
Lift-Arc TIG
GTAW
Output On
Amps
% Panel Amps
TIG
GTAW
Remote 14
Amps
% Panel Amps
Stick−Remote
SMAW
Remote 14
Amps
% Panel Amps
Subarc
SAW
Remote 14
Volts
Volts
MIG
GMAW/FCAW
Remote 14
Volts
Volts
*See Section 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 Stick Remote, Stick Output On, TIG Remote and Gouge
modes. When the unit is configured for low OCV operation, a low sensing voltage (approximately 12 VDC) is present between the electrode and
the workpiece prior to the electrode touching the workpiece. Consult a Factory Authorized Agent for information regarding how to configure unit
for low OCV welding operation.
OM-263 655 Page 25
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 Stick Remote: The right
meter displays the preset amperage set with the panel Adjust
Control. When connected, the remote control sets the percentage of preset amperage. The Remote In Use indicator is lit while
the remote control is connected.
C 2
This is the default configuration as shipped from the factory.
SMAW (Stick) and CAC-A (Gouge): The remote amperage
control is ignored. The Remote In Use indicator is not lit. The
right meter displays the preset amperage.
Stick Remote: The right meter displays the preset amperage set
with the panel Adjust Control. When connected, the remote control sets the percentage of preset amperage. The Remote In Use
indicator is lit while the remote control is connected.
C 3
SMAW (Stick) and CAC-A (Gouge): The remote amperage
control is ignored. The Remote In Use indicator is not lit. The
right meter displays the preset amperage.
Stick Remote: The right meter displays the percentage of
preset amperage with a remote connected. The remote control sets the percentage of preset amperage. The Remote In
Use indicator is lit while the remote control is connected. Turning the panel Adjust Control will briefly display the preset amperage for 100%.
. Configurations 2 and 3 prevent a wire feeder from affecting the preset amperage of the Stick and Gouge Output-On modes.
OM-263 655 Page 26
SECTION 7 − GTAW OPERATION
7-1. Typical Connection For GTAW Process
4
3
1
2
6
5
7
8
263 325-A
!
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-263 655 Page 27
7-2. TIG Remote Welding Mode - GTAW Process
1
2
3
85
263 561-B
!
Weld terminals are energized
through the remote control in TIG
Remote welding mode.
1
2
3
Mode Switch
Right Display
Adjust Control
Setup
For typical system connections refer to
Section 7-1.
Rotate Mode Switch to TIG Remote position as shown.
The preset amperage is shown in the Right
Display.
Operation
The Adjust Control is used to set desired
preset amperage.
A remote control is required to turn on the
weld output.
. If the remote control has an amperage
adjustment, the adjustment will function as a percentage of the preset amperage. The Remote In Use indicator
will be lit.
. For
best results, gently scratch the
tungsten electrode to the work to initiate an arc. To minimize arc flare at the
end of the weld, pull back the electrode
quickly to extinguish the arc.
OM-263 655 Page 28
7-3. Lift-Arc TIG Welding Mode - GTAW Process
1
2
12.0
3
4
85
263 561-B
6
“Touch”
1−2
Seconds
5
Do NOT Strike Like A Match!
!
Weld terminals are energized at all
times in Lift Arc TIG welding mode.
1
2
3
4
5
6
Mode Switch
Left Display
Right Display
Adjust Control
Workpiece
Tungsten Electrode
Setup
For typical system connections refer to
Section 7-1.
Rotate Mode Switch to LIFT-ARC TIG position as shown.
The open-circuit voltage is shown in the
Left Display. Preset amperage is shown in
the Right Display.
Normal open-circuit voltage is not present
before the electrode touches the workpiece, instead a low sensing voltage is
present. The sensing voltage allows the
electrode to touch the workpiece without
overheating, sticking, or getting contaminated.
Operation
The Adjust Control is used to set desired
preset amperage.
. If a remote control is used for amper-
age adjustment, the adjustment will
function as a percentage of the preset
amperage. The Remote In Use indicator will be lit.
. For best results, firmly touch the tung-
sten electrode to the workpiece at the
weld start point. Hold electrode to
workpiece for 1-2 seconds, and lift
electrode. An arc will form when the
electrode is lifted. To minimize arc flare
at the end of the weld, pull back the
electrode quickly to extinguish the arc.
OM-263 655 Page 29
SECTION 8 − GMAW/FCAW OPERATION
8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process
9
1
2
3
8
7
4
6
5
269 323-A
!
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-263 655 Page 30
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. MIG Remote Welding Mode - GMAW/FCAW Process
1
2
3
4
25.0
263 561-B
Rotate Mode Switch to MIG Remote position as shown.
!
Weld terminals are energized
through the remote control in MIG
Remote welding mode.
1
Mode Switch
The preset voltage is shown in the Left Display.
2
Left Display
Operation
3
Adjust Control
4
Arc Control
The Adjust Control is used to set desired
preset voltage.
Setup
For typical system connections refer to
Section 8-1.
. The preset voltage can be adjusted re-
motely at the wire feeder if the feeder
has a voltage control. This voltage control will override the Adjust Control of
preset voltage on the welding power
source. The Remote In Use indicator
will be lit.
Arc Control − Inductance
Inductance control allows the arc characteristics, soft versus stiff, to be changed for
specific applications and wires. The star
setting is good for most applications. Use
soft settings (0−25) to soften the arc and increase puddle fluidity. Use stiff settings
(0−25) to stiffen the arc and reduce puddle
fluidity.
OM-263 655 Page 31
8-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process
10
1
9
2
4
8
3
7
5
6
269 324-A
!
Turn off power before making connections.
1
2
3
4
5
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
Ground Cable to Workpiece
Workpiece
Voltage Sensing Clamp
OM-263 655 Page 32
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. MIG-Gas Output On Welding Mode - GMAW/FCAW Process
1
2
3
4
25.0
263 561-B
!
Weld terminals are energized at all
times in MIG-Gas Output On welding mode.
1 Mode Switch
2 Left Display
3 Adjust Control
4 Arc Control
Setup
For typical system setup connections refer
to Section 8-3.
Rotate Mode Switch to MIG-Gas Output
On position as shown.
The Left Display toggles between open circuit voltage and preset voltage.
Operation
The Adjust Control is used to set desired
preset voltage.
. The Left Display toggling momentarily
Arc Control − Inductance
Inductance control allows the arc characteristics, soft versus stiff, to be changed for
specific applications and wires. The star
setting is good for most applications. Use
soft settings (0−25) to soften the arc and increase puddle fluidity. Use stiff settings
(0−25) to stiffen the arc and reduce puddle
fluidity.
pauses while the preset voltage is adjusted.
OM-263 655 Page 33
8-5. MIG-No Gas Output On Welding Mode - GMAW/FCAW Process
2
1
3
4
25.0
263 561-B
!
Weld terminals are energized at all
times in MIG-Gas Output On welding mode.
1 Mode Switch
2 Left Display
3 Adjust Control
4 Arc Control
Setup
For typical system setup connections refer
to Section 8-3.
OM-263 655 Page 34
Rotate Mode Switch to MIG-No Gas Output
On position as shown.
The Left Display toggles between open circuit voltage and preset voltage.
Operation
The Adjust Control is used to set desired
preset voltage.
. The Left Display toggling momentarily
pauses while the preset voltage is adjusted.
Arc Control − Inductance
Inductance control allows the arc characteristics, soft versus stiff, to be changed for
specific applications and wires. The star
setting is good for most applications. Use
soft settings (0−25) to soften the arc and increase puddle fluidity. Use stiff settings
(0−25) to stiffen the arc and reduce puddle
fluidity.
SECTION 9 − SMAW/CAC-A OPERATION
9-1. Typical Connection For SMAW And CAC-A Process
5
4
3
2
1
6
7
269 326-A
!
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-263 655 Page 35
9-2. Stick Remote Welding Mode - SMAW Process
1
2
3
4
85
263 561-B
!
Weld terminals are energized
through the remote control in Stick
Remote welding mode.
1
Mode Switch
2
Right Display
3
Adjust Control
4
Arc Control
Setup
For typical system connections refer to
Section 9-1.
Rotate Mode Switch to Stick Remote position as shown.
The preset amperage is shown in the Right
Display with the Amps Indicator lit.
OM-263 655 Page 36
Operation
The Adjust Control is used to set desired
preset amperage.
A remote control is required to turn on the
weld output.
. If the remote control has an amperage
adjustment, the adjustment will function as a percentage of the preset amperage. The Remote In Use indicator
will be lit.
Adaptive Hot Start automatically increases
welding amperage at the start of a weld.
This helps eliminate electrode sticking during arc initiation.
. For best results at the end of the weld,
pull back the electrode quickly to extinguish the arc.
Arc Control − Dig
Dig control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and electrodes. The star setting is good for most applications. Use soft
settings (0 to 25) for smooth running electrodes like E7018. Use stiff settings (0 to
25) for penetrating electrodes like E6010.
9-3. Stick-Output-On Welding Mode - SMAW Process
1
2
84.5
3
4
5
85
263 561-B
!
Weld terminals are energized at all
times in Stick-Output-On welding
mode.
1 Mode Switch
2 Left Display
3 Right Display
4 Adjust Control
5 Arc Control
Setup
For typical system connections refer to
Section 9-1.
Rotate Mode Switch to Sick-Output-On
position as shown.
The open circuit voltage is shown in the Left
Display and the preset amperage is shown
in the Right Display.
Operation
The Adjust Control is used to set desired
preset amperage.
Adaptive Hot Start automatically increases
welding amperage at the start of a weld.
This helps eliminate electrode sticking during arc initiation.
Arc Control − Dig
Dig control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and electrodes. The star setting is good for most applications. Use soft
settings (0 to 25) for smooth running electrodes like E7018. Use stiff settings (0 to
25) for penetrating electrodes like E6010.
. For best results at the end of the weld,
pull back the electrode quickly to extinguish the arc.
OM-263 655 Page 37
9-4. Gouge Mode - CAC-A Process
1
2
84.5
3
4
350
263 561-B
!
Weld terminals are energized at all
times in Gouge mode.
1
Mode Switch
2
Left Display
3
Right Display
4
Adjust Control
OM-263 655 Page 38
Setup
For typical system connections refer to
Section 9-1.
Rotate Mode Switch to Gouge position as
shown.
The open circuit voltage is shown in the Left
Display and the preset amperage is shown
in the Right Display.
Operation
The Adjust Control is used to set desired
preset amperage.
SECTION 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
269 792-A
!
1
2
Turn off power before making connections.
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
3
4
5
6
Ground Cable to Workpiece
Workpiece
Wire Drive Assembly
10 Pin Motor Control Cord
7
8
9
10
Saw Control
Flux System
Flux Valve
14 Pin/115V Y−Cord
OM-263 655 Page 39
10-2. Subarc Welding Mode − SAW Process
1
2
3
25.0
263 561-B
!
Weld terminals are energized
through the remote control in Subarc welding mode.
1 Mode Switch
2 Left Display
3 Adjust Control
Setup
For typical system connections refer to
Section 10-1.
OM-263 655 Page 40
Welding Power Source
Rotate Mode Switch to Subarc position as
shown.
The preset voltage is shown in the Left Display.
SAW Controller
When using Miller Electric HDC DX controller, select Dimension 652 or SubArc DC
650 for power source selection.
. This product is not compatible with
digital series of subarc equipment.
Operation
Adjust preset voltage remotely at the SAW
controller. This voltage control will override
the Adjust Control of preset voltage on the
welding power source. The Remote In Use
indicator will be lit. See SAW controller
Owner’s Manual for additional information.
SECTION 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.
269 319-A
OM-263 655 Page 41
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-263 655 Page 42
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 4-7). Operation will
continue when the unit has cooled.
Indicates the auxiliary circuit has overheated.
The unit has shut down to allow the fan to cool
it. Operation will continue when the unit has
cooled.
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-7). Operation will
continue when the unit has cooled.
Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. If this display is
shown, contact a Factory Authorized Service
Agent.
Help 25 Display
Indicates machine has reached Duty Cycle
limit (See Section 4-7). 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 5-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-9).
Check for proper input power connections (see Section 5-9).
No weld output; meter display On.
Input voltage outside acceptable range of variation (see Section 5-8).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-7).
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 5-7).
No 115 volts AC output at duplex receptacle.
Reset supplementary protector CB1 (see Section 5-7).
Auxiliary circuit overheated. Allow unit to cool with fan on (see Section 4-7).
Notes
OM-263 655 Page 43
SECTION 12 − ELECTRICAL DIAGRAMS
Figure 12-1. Circuit Diagram For Dimension 650 CC/CV 380/460V
OM-263 655 Page 44
263 636-C
OM-263 655 Page 45
SECTION 13 − PARTS LIST
. Hardware is common and
not available unless listed.
13
12
14
11
15
18
10
17
16
19
29
9
28
26
31
30
25
20
27
24
32
23
8
21
34
33
35
22
36
6
37
7
5
44
38
39
4
40
41
42
3
43
2
1
269 849-A
Figure 13-1. Main Assembly
OM-263 655 Page 46
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly
. . 1 . . . . . . . . . . . . . . 267295
. . 2 . . . . . . . . . . . . . . 263624
. . 3 . . FM1,FM2 . . 213072
. . . . . . RC12, RC13 . 135635
. . 4 . . . . . . See Figure 13-2
. . 5 . . . . . . . . . . . . . . 176226
. . 6 . . . . RC2 . . . . 143976
. . 7 . . . . . S1 . . . . . 244920
. . 8 . . . . . . See Figure 13-4
. . 9 . . . . . . . . . . . . . . 263647
. . . . . . . . . . . . . . . . . . . 263620
. . . . . . . . . . . . . . . . . . . 234534
. . . . . . . . . . . . . . . . . . . 217136
. . . . . . . . . . . . . . . . . . . 175256
. . . . . . . . . . . . . . . . . . . 269927
. . 10 . . . . . . . . . . . . . . 263646
. . . . . . . . . . . . . . . . . . . 263619
. . . . . . . . . . . . . . . . . . . 234534
. . . . . . . . . . . . . . . . . . . 217136
. . 11 . . . . . . . . . . . . . . 267339
. . 12 . . . . . . . . . . . . . +263606
. . 13 . . . . . . . . . . . . . . 258427
. . 14 . . . . . . . . . . . . . . 232914
. . 15 . . . . . . . . . . . . . . 266958
. . 16 . . . . . . . . . . . . . . 269267
. . 17 . . . . . . . . . . . . . . 186711
. . 18 . . . . . . . . . . . . . . 147195
. . 19 . . . . . . . . . . . . . . 263626
. . 20 . . . . . . . . . . . . . . 154022
. . 21 . . . . . . . . . . . . . +263598
. . 22 . . . . . . . . . . . . . . 267340
. . 23 . . . . . . . . . . . . . . 214918
. . 24 . . . . . . . . . . . . . . 265204
. . 25 . . . . CB1 . . . . 093996
. . 26 . . . . CB2 . . . . 083432
. . . . . . . . . C17 . . . . 270072
. . 27 . . . . . . . . . . . . . . 145743
. . 28 . . . . . W1 . . . . . 180270
. . 29 . . . . . W2 . . . . . 255744
. . 30 . . . . . . . . . . . . . . 269378
. . 31 . . . . . . . . . . . . . . 269928
. . 32 . . . . . . . . . . . . . . 269789
. . 33 . . . . . . . . . . . . . +263610
. . 34 . . . . FM3 . . . . 183918
. . . . . . . . . RC14 . . . . 135635
. . 35 . . . . . . . . . . . . . . 263623
. . 36 . . . . . . . . . . . . . . 263652
. . 37 . . . . . . . . . . . . . . 263653
. . 38 . . . . . . . . . . . . . . 269262
. . 39 . . . . . . . . . . . . . . 263597
. . 40 . . . . . . . . . . . . . . 264243
. . 41 . . . . . . . . . . . . . . 269271
. . 42 . . . . . . See Figure 13-3
. . 43 . . . . PC2 . . . . 263632
. . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fan, Muffin 115V 60Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . .
. . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Front W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, Lh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side Rh (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, Side Folded Edge Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Miller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Warning Electric Shock (Eng/Fr) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Warning Electric Shock & Input (En/Fr) . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side Lh (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, Side Folded Edge Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Miller (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Warning Electric Shock (Eng/Fr) (Not Shown) . . . . . . . . . . . . . . .
. . Bracket, Corner Front (Casting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Top Folded Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Falling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Seal, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Lift Eye Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, 115VAC/20A Rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Cb1 + Cb2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 375−27 .54Hex .25H Nyl Flange .62D . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Rating Card 380/460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Receptacle Duplex GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Hf Lead Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rcpt, Str Dx Grd 2P 3W 20A 125V *5−20R . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ring, Aux Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Supplementary Pro, Man Reset 1P 20A 250 VAC Frict . . . . . . . . . . . . . . .
. . Supplementary Pro, Man Reset 1P 10A 250 VAC Frict . . . . . . . . . . . . . . .
. . Capacitor Assy, W/Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Lug, Univ W/Scr 600V 2-14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . .
. . Contactor, Def Prp 40A 3P 24 VAC Coil W/Boxlug . . . . . . . . . . . . . . . . . . .
. . Relay, Encl 24 VDC Spst 30A/300Vac 4Pin Flange Mtg . . . . . . . . . . . . . . .
. . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Electric Shock/Exploding Parts (Fr) . . . . . . . . . . . . . . . . . .
. . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Fan 24VDC 3000 RPM 43 Cfm W/10 Ohm Resistor . . . . . . . . . . . .
. . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Foam Rubber (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Base/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Base, W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bus Bar, Stabilizer/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Windtunnel/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, Rh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-263 655 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (Continued)
. . . . . . . . . PLG5 . . . . 241169 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG3, PLG4 241171 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG1 . . . . 241172 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG2 . . . . 131054 . . Housing Rcpt + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . T2 . . . . . 263618 . . XFMR, Control 380/460 VAC Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG10 . . . 131204 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC10 . . . . 131203 . . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC11 . . . . 135635 . . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG7 . . . . 241170 . . 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-263 655 Page 48
. Hardware is common and
1
not available unless listed.
2
16
15
3
4
14
5
6
7
8
9
13
10
12
11
269 850-A
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 . . . . . . . . . . . . . . 186275 . . Label, Remote 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 174991 . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip-.21 . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . . . 268891 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 11 . . . . . . . . . . . . . . 264114 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . . . . . . . . . . . 263560 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 263570 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 190512 . . Stand-off, No 6-32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . . 4
. . 15 . . . . . . . . . . . . . . 231470 . . Nut, Adapter Encoder Shaft Mtg 375-32 To 500-28 . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . PC1 . . . . 263562 . . Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG56 . . . 241167 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG59, PLG53 241168 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG60 . . . 241169 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG57 . . . 241170 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG55 . . . 241171 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG54 . . . 241172 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG58 . . . 269989 . . Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . C13,C14 . . 267745 . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . VR1, VR2 . . 270076 . . Varistor, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 263611 . . Plug, W/Leads (Voltage Feedback) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 263613 . . Cable Assy, Current Feedback W/Ferrite Core . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 266925 . . Plugs, W/Leads & Current Xfmrs (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . CT1, CT2 . . 266798 . . . . XFMR, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 269893 . . Screw, 500−13x1.00 (Not Shown) Output Stud Hardware . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 222794 . . Nut, 500−13.75 Hex (Not Shown) Output Stud Hardware . . . . . . . . . . . . . 2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-263 655 Page 49
. Hardware is common and
not available unless listed.
3
1
4
5
2
6
12
7
11
8
9
10
269 852-A
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 18.00in2500v . . . . . . . . . . . . . . . . 1
. . 3 . . . . . Z1 . . . . . 263583 . . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . L1 . . . . . 263588 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 263578 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . . 2
. . 7 . . . . . . . . . . . . . . 170647 . . Bushing, Snap-in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 264199 . . Stand-off, Insul Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 268532 . . Nut, 375-16 .63Hex 1.13H Stl Pld Clr Coupling . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . PM1−PM4 . 269905 . . Kit, Transistor IGBT Module (Powerx) (2 Modules) . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 263581 . . Plugs, W/Leads (Gate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . SR1 . . . . 184260 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-263 655 Page 50
. Hardware is common and
not available unless listed.
15
14
13
11
12
16
1
10
17
18
2
3
4
5
6
7
8
9
269 851-B
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 . . . . . . . . . . . . . . 269789 . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 269928 . . Label, Warning Electric Shock/Exploding Parts (Fr) . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109T Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 2
. . 6 . . . . . . . . . . . . . . 263571 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 7 . . . . HD1 . . . . 168829 . . Transducer, Current 1000A Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 264242 . . Bracket, Mtg Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 263559 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 196355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 11 . . . . . T1 . . . . . 269226 . . Xfmr Assy, Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 263556 . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 R1/C15,R2/C16 266955 . . Resistor/Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 14 . . . . RT2 . . . . 173632 . . Thermistor, Ntc 30K Ohm @ 25 Deg C 12.00in Lead . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC70 . . . . 135635 . . Housing Plug + Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 263554 . . Heat Sink, Rect Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . D1−D4 . . . 201531 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 17 . . . . . . . . . . . . . . 199840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 18 . . . . . R3 . . . . . 270758 . . Resistor W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG71 . . . 131204 . . 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-263 655 Page 51
Notes
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
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since 1930!
Notes
Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Torches
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2015-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2015 Miller Electric Mfg. Co.
2015−01
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