Miller | MH120000G | Owner Manual | Miller PIPEWORX 350 FIELDPRO AND FIELDPRO REMOTE CE User manual

Miller PIPEWORX 350 FIELDPRO AND FIELDPRO REMOTE CE User manual
OM-263657K
2017−02
Processes
Multiprocess Welding
Description
Arc Welding Power Source
PipeWorx 350 FieldProt
t
And FieldPro Remote
CE
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Multiprocess
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Proper Method To Carry Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Weld Output Receptacles And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. TIG Lift-Arct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Connecting Work Sense Lead To Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Optional Method Of Combining Work Sense Lead With Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Connecting Basic Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Setting Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Installing Welding Power Source Onto Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Connecting To Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Volt Sense Lead And Work Cable Connections For Multiple Welding Arcs . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Welding Power Source And Remote Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Welding Power Source And Remote Interface Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Lift-Arc TIG Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Carbon Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Restoring Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Viewing Software Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
8
9
9
9
10
10
10
10
11
12
13
13
14
14
15
16
18
18
19
20
21
21
22
22
23
24
25
27
27
28
29
29
30
30
30
TABLE OF CONTENTS
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Welding Power Source And Remote Diagnostics Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Feeder Diagnostics Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Troubleshooting Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Troubleshooting Welding Power Source Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Power Source Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Updating Software In Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
31
31
31
32
33
33
34
34
35
36
40
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
907633
Product
PIPEWORX 350 FIELDPRO (CE)
Council Directives:
·2014/35/EU Low voltage
·2014/30/EU Electromagnetic compatibility
·2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
February 14, 2017
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
264239C
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
301176
Product
FIELDPRO REMOTE (CE)
Council Directives:
·2014/35/EU Low voltage
·2014/30/EU Electromagnetic compatibility
·2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
February 14, 2017
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
269307C
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
PIPEWORX 350 FIELDPRO DINSE CE
Stock Number
907633
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.14
Health Ef­
fects
10 cm
0.08
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.14
3 cm
0.08
3 cm
0.17
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
6 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275553-A
Tony Samimi
Date tested:
2016-03-01
144 cm
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-267533 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-267533 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-267533 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-267533 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
OM-267533 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surOM-267533 Page 6
chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
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.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
OM-267533 Page 7
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-267533 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Environmental Protection Use Period (China)
Safe123 2016−06
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
Single / Three
Phase Static
Frequency
Converter-Transformer-Rectifier
1/
SD Logo Is A
Trademark Of The
SD−3C, LLC
Amperage
Off
Line Connection
V
Voltage
I1eff
%
I2
On
Protective Earth
(Ground)
U2
U1
Hz
Conventional
Load Voltage
X
Percent
Rated Welding
Current
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG) Welding
Duty Cycle
Alternating
Current (AC)
Maximum Effective Supply Current
/
Single / Three
Phase
Primary Voltage
Single Phase
Hertz
Direct Current
(DC)
Three Phase
U0
Rated No Load
Voltage (OCV)
Gas Metal Arc
Welding (GMAW)
S
Suitable for Some
Hazardous
Locations
I1max
IP
Rated Maximum
Supply Current
Internal Protection
Rating
Shielded Metal
Arc Welding
(SMAW)
OM-263657 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the rear. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-4 and 5-5 for information on connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Input
Power
3-Phase
Rated Output
350 A at 34
VDC, 60%
Duty Cycle*
Voltage
Range in CV Mode
Amperage
Range in
CC Mode
Max. OpenCircuit
Voltage
10−44 V
10−350 A
78 VDC
RMS Amps Input at Rated Load
Output, 50/60 Hz 3-Phase at
NEMA Load Voltages and Class I
Rating
380 V
400 V
KVA
KW
27.1
25.9
17.8
15.9
*See Section 4-3 for Duty Cycle Rating.
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops, a
Help message is displayed and
cooling fan runs. Wait fifteen
minutes for unit to cool. Reduce
amperage or voltage, or duty cycle
before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
60% Duty Cycle
6 Minutes Welding
Overheating
4 Minutes Resting
A or V
0
15
Minutes
OR
Reduce Duty Cycle
Ref. 216568-A
OM-263657 Page 10
4-4. Dimensions And Weight
Power Source
100 lb (45.4 kg)
22 in.
(559 mm)
17 in.
(432 mm)
12 in.
(305 mm)
Remote
9.08 lb (4.12 kg)
9.75 in.
(247.7 mm)
11.6 in.
(294.6 mm)
4.6 in.
116.8 mm)
18 in.
(457.2 mm)
18 in.
(457.2 mm)
Ref. 255179-B / Ref. 255429-B
OM-263657 Page 11
4-5. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23 2014−06
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 33.98 mW (or the short−circuit power Ssc is greater than
4,708,376 VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator
if necessary, that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
C. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
D. Temperature Specifications
Operating Temperature Range*
Storage Temperature Range
14 to 104°F (−10 to 40°C)
−4 to 131°F (−20 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
OM-263657 Page 12
Temp_2016- 07
SECTION 5 − INSTALLATION
5-1. Selecting a Location
Movement
2
!
2
Do not move or operate unit
where it could tip.
OR
1
3
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Lifting Forks
Location And Airflow
4
Extend forks beyond opposite side
of unit.
2
Lifting Handles
Use handles to lift unit.
3
Hand Cart
Use cart or similar device to move
unit.
4
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
18 in.
(460 mm)
loc_med 2015-04 / Ref. 255179-B
OM-263657 Page 13
5-2. Proper Method To Carry Remote
1
Handle
Carry Remote only by using the
handle.
1
255409-B
5-3. Remote 14 Receptacle Information
A
K
Socket*
J
Socket Information
I
B
H
C L N
D M
G
E F
Ref. 255179-B
OM-263657 Page 14
14 volts DC. Circuit limited to 35 mA.
B
Contact closure to A completes contactor control
circuit.
C
Output to remote control; +10 volts DC.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from
remote control.
14 VOLTS DC
REMOTE
OUTPUT
CONTROL
*The remaining sockets are not used.
A
5-4. Electrical Service Guide
Elec Serv 2017-01
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 available.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
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 3 Phase
Input Voltage (V)
380
400
Rated Maximum Supply Current I1max (A)
27.1
25.4
Maximum Effective Supply Current I1eff (A)
14.9
13.9
30
30
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses2
Normal Operating Fuses
3
40
40
Min Input Conductor Size In AWG (mm2) 4
14(2)
14(2)
Max Recommended Input Conductor Length In Feet (Meters)
81(25)
91(28)
14(2)
14(2)
Min Grounding Conductor Size In AWG
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
OM-263657 Page 15
5-5. Connecting 3-Phase Input Power
3
= GND/PE Earth Ground
4
7
2
L1
3
L2
5
L3
6
1
Tools Needed:
input2 2012−05 − 803766-C / Ref. 255179-B
OM-263657 Page 16
5-5. Connecting 3-Phase Input Power (Continued)
!
!
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be connected to any input power between 208 and
575 VAC without removing cover to relink the
power source.
See rating label on unit and check input voltage available at site.
5
Input Conductors (L1, L2 And L3)
6
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
For Three-Phase Operation
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
1
Input Power Cord.
7
2
Disconnect Device (switch shown in the
OFF position)
Select type and size of over-current protection using Section 5-4 (fused disconnect
switch shown).
3
Green Or Green/Yellow Grounding
Conductor
4
Disconnect Device Grounding Terminal
Over-Current Protection
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
input2 2012−05
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-263657 Page 17
5-6. Weld Output Receptacles And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
150 ft
(45 m)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x3/0 (3x95)
600
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02
5-7. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Electrode Output Terminal
2
Work Output Terminal
. For welding output terminal connec-
tions see Sections 5-8 thru 5-12 for
typical connection processes.
1
2
output term1 2015−02 / Ref. 255179-B
OM-263657 Page 18
5-8. Stick Connections
1
Work Output Terminal
Connect work lead to work output
terminal.
2
Electrode Output Terminal
Connect electrode holder
electrode output terminal.
to
2
1
255358-B
Notes
OM-263657 Page 19
5-9. TIG Lift-Arct Connections
1
Work Output Terminal
Connect work lead to work output
terminal.
2
Electrode Output Terminal
Connect TIG torch with gas valve to
electrode output terminal.
3
4
Gas Cylinder
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5
6
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
Connect torch gas
regulator/flowmeter.
5
6
4
7
hose
to
Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.
3
2
7
1
Tools Needed:
11/16 in., 1-1/8 in., (21 mm)
255357-B
OM-263657 Page 20
5-10. Connecting Work Sense Lead To Remote
. The
work sense lead is required for operation of the
FieldPro Remote.
1
2
Lead
Ring Terminal 1/2 in.
If using a ring terminal, slide
terminal onto post on the remote.
3
3
Wing Nut
Once terminal or wire is on post,
tighten wing nut.
4
2
5
2
1
4
5
5
Binding Post
Electrical Tape Or Heat Shrink
Tubing
If ring terminal is cut or broken, the
bare wire can be looped around the
post and tightened under the wing
nut.
255450-A
5-11. Optional Method Of Combining Work Sense Lead With Work Clamp
1
2
Work Sense Clamp
Ring Terminal 1/2 in.
Disconnect ring terminal from
clamp.
3
4
5
1
Work Sense Lead
Work Cable
Work Clamp
. Be sure that work sense lead
ring terminal is on top of work
cable ring terminal when
connecting to clamp.
2
Connect work sense lead and work
cable to work clamp.
3
5
4
Tools Needed:
3/8 in.
255449-A
OM-263657 Page 21
5-12. Connecting Basic Feeder
!
Turn Off wire feeder and
welding power source. Stop
engine on welding
generator.
1
2
3
4
Welding Power Source
Gas Hose
Weld Cable To Feeder
Work Cable To Workpiece
Weld cable and work cable connections to power source (DCEN/
DCEP) are dependant on wire type.
. Since feeder is not polarity sensitive, there is no need for an
electrode polarity switch.
1
5
6
Workpiece
Voltage Sensing Clamp
Connect voltage sensing clamp to
workpiece.
3
7
8
9
Gun
Gun Trigger Receptacle
FieldProt Feeder (See
OM258944 For Feeder
Operation)
10 Gas Cylinder
10
Use of shielding gas is dependant
on wire type.
. Shielding gas pressure not to
2
exceed 100 psi (689 kPa).
4
8
9
6
7
5
258966-A
5-13. Setting Inductance
The power source will display ACC when a FieldPro Feeder is connected to the power source. Press either the Up or Down arrow key to set the
inductance within the range of 0 to 99.
OM-263657 Page 22
5-14. Installing Welding Power Source Onto Rack
Rack − 195466 Universal Inverter
Rack
Mounting Kit − 301100
One Kit Per Machine
(See OM-259463 For rack
setup and operation)
Have only qualified persons make
this installation.
1
!
Turn Off welding power
sources before inspecting or
installing rack.
1
Rear Rack Mounting Bracket
Loosely attach one rack mounting
bracket (with the weld nuts facing
up) on the back of the rack with 2
screws.
2
2
Welding Power Source
Slide power source onto rack in front
of the bracket.
Align the channels of the rear base
brackets with the rack mounting
bracket. Push the power source
back so the mounting bracket slides
into the channels.
3
Front Rack Mounting Bracket
Slide the second rack mounting
bracket (with the weld nuts facing
up) into the channels on the front
base brackets. Attach bracket to
rack using 2 screws. Tighten all 4
bracket screws to 10 ft lb (13.6 N⋅m).
1
3
Rear Of Power Source And Rack
Hole Layout For 4-Pack Rack
Front Of Power Source And Rack
Hole Layout For 6-Pack Rack
Tools Needed:
1/2 in.
259422-A / 254712-A
OM-263657 Page 23
5-15. Connecting To Remote
This power source can be used with
either the FieldPro Remote,
RHC−14 remote, or wireless
remote (see RHC−14 remote or
wireless remote Owner’s Manual
for operating instructions).
1
2
3
RHC-14 Or Wireless Remote Connection
Power Source
TIG Torch (Shielding Gas Not
Shown)
Electrode Holder
When using an RHC-14 or wireless
remote, connect TIG torch or
electrode holder directly to the
ELECTRODE
(top)
output
receptacle.
2
1
4
Work Cable
Connect work cable to WORK
(bottom) output receptacle on the
front of the welding power source.
Attach work cable clamp as close to
the arc as possible.
3
5
6
Work Sense Lead
When using a FieldPro Remote,
attach work sense lead clamp next
to the work cable clamp. Connect
the other end of the work sense
lead to the binding post on the side
of the FieldPro Remote.
6
4
RHC−14 Remote Or Wireless
Remote
Connect RHC-14 or wireless
remote to 14-pin receptacle on the
front of the power source.
7
FieldPro Remote
Connect one end of the weld cable
to ELECTRODE (top) output
receptacle on the front of the power
source and the other end to the
FieldPro Remote. Connect the TIG
torch or electrode holder to the
other side of the FieldPro Remote.
FieldPro Remote Connection
1
. The
RHC-14 or wireless remote can be used with the
FieldPro Remote to allow amperage adjustment during
welding.
4
5
2
3
7
255420-B
OM-263657 Page 24
5-16. Volt Sense Lead And Work Cable Connections For Multiple Welding Arcs
A. Ideal Setup
1
2
5
1
4
6
3
2
5
4
3
255378-B
1
Welding Power Source
2
Weld Cable
3
Work Cable
4
Work Sense Lead
The work sense lead is required for
operation of the FieldPro Remote.
5 Remote
6 Workpiece
This arrangement is an ideal setup for
multiple welding arcs.
OM-263657 Page 25
B. Bad Setup
1
2
3
1
5
2
4
5
6
4
3
255379-B
1
2
3
Welding Power Source
Weld Cable
Work Cable
OM-263657 Page 26
4
5
6
Work Sense Lead
Remote
Workpiece
This arrangement is a bad setup. Clamps
for separate units should not be shared.
Weld cables should not be crossed.
SECTION 6 − OPERATION
6-1. Welding Power Source And Remote Interface Controls
2
3
4
8
9
5
I
ON
1
12
11
6
7
10
OFF
255429-B / 264180-B / Ref. 255179-B / 253664-A
1
Power Switch
2
AMPS Display
3
TIG Process Select Button
4
Stick Process Select Button
5
6
7
8
Stick Electrode Type Select Button
Amperage Adjustment Buttons
14-Pin Remote Connected Indicator
FieldPro Accessory Connected
Indicator
9
IN USE Button
10 IN USE Indicator
11 Check Polarity Indicator
12 Stick Negative Indicator
OM-263657 Page 27
6-2. Welding Power Source And Remote Interface Operation Description
Power Switch
Use this switch to power up or power down the welding power source.
. The fan is thermostatically controlled and only runs when cooling is needed.
AMPS Display
This display illuminates and shows amperage for either TIG or stick welding process. Measured amperage just
prior to the end of a welding operation will appear on the display for ten seconds after welding operation.
TIG Process Select Button
Press and release this button to activate the TIG welding process controls. The TIG text below the button
illuminates. Adjust the amperage to the appropriate setting within a range from 10 to 350 amps. If the TIG
process has been selected and a remote current/contactor control is connected, holding the TIG process select
button for more than two seconds will display the effective amperage command (based on the amperage setting
and the remote current/contactor control setting).
Stick Process Select
Button
Press and release this button to activate the stick welding process controls. The STICK text below the button
illuminates as well as the active stick electrode type text. Select the desired stick electrode type and adjust the
amperage to the appropriate setting within a range from 40 to 350 amps.
Stick Electrode Type
Select Button
Press and release button to select the desired stick electrode type (EXX10 or EXX18). The text above or below
the button will illuminate for the active electrode type. This button is only active with the stick welding process
and only then will text for the electrode type illuminate.
.
Adjustable DIG and
Hotstart
There may be a “clunk” sound from the power source when switching between Stick and TIG
processes. This is part of normal power source operation.
Press and hold the STICK button for a few seconds to enter adjustable DIG. The right decimal point will
illuminate on the display to indicate DIG. Once in adjustable DIG, press and release the STICK button again
to enter adjustable Hotstart. The middle decimal point will illuminate on the display to indicate Hotstart.
Pressing and releasing the STICK button a third time will exit the menu. The menu will automatically exit
after 10 seconds of inactivity. Pressing and releasing any button other than the STICK button while in the
menu will also exit the menu.
Amperage Adjustment
Buttons
Use these buttons to set the desired amperage setting for either TIG or stick welding process.
14-Pin Remote Connected
Indicator
The 14-PIN REMOTE text will illuminate when there is a 14-pin accessory connected to the Remote 14
receptacle on the power source.
FieldPro ACCESSORY
Connected Indicator
The FieldPro ACCESSORY text will illuminate when there is a FieldPro accessory connected to and properly
communicating with the power source.
IN USE Button
Press and release this button on the power source or FieldPro Remote to illuminate the IN USE text. Press and
release again to turn IN USE text off. This lets others know that the machine is being used.
IN USE Indicator
Light automatically turns on when arc is struck. Toggle light using the IN USE button during use. Light will automatically turn off after four hours of inactivity.
CHECK POLARITY
Indicator
The CHECK POLARITY text will illuminate along with an error message (Err) if the work and electrode leads are
reversed. This will light only if a FieldPro accessory is connected. Power down and correct the connections (see
Section 5 for proper connections).
STICK NEGATIVE
Indicator
The DCEN (−) STICK NEG text will illuminate if the polarity is negative while in STICK mode. To activate DCEN
mode, press the STICK button and down arrow at the same time. Press the STICK button to exit this mode. The
DCEN mode can be used for EXX10 and/or EXX18 process setting. The mode has to be set for each electrode
process individually.
NOTICE − Controls on the FieldPro Remote are NOT adjustable during welding. To make adjustments during welding, use the power source controls.
Adjustments can be made if using the RHC-14 remote or wireless remote.
Table 6-1. Recommended Process Selections vs Electrode Type
OM-263657 Page 28
Electrode Type
Suggested Process Setting
EXXX1
EXX10
EXXX2
EXX10
EXXX3
EXX18
EXXX4
EXX18
EXXX5
EXX18
EXXX6
EXX18
EXXX7
EXX18
EXXX8
EXX18
Stainless
EXX18
6-3. Lift-Arc TIG Procedure
With Process Switch in the TIG
position, start an arc as follows:
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point. Arc will not
start while electrode is touching the
workpiece. Slowly lift electrode to
form an arc.
. Do not re-touch the electrode to
1
“Touch”
1
the workpiece. The arc will go
out and the electrode will stick.
2
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Second
. If
FieldPro
Remote
is
connected, its display may
temporarily turn off when the
tungsten touches the workpiece.
Do NOT Strike Like A Match!
Ref. S-156279
6-4.
Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.
1
2
3
OM-263657 Page 29
6-5.
Carbon Arc Gouging
1
Direction Of
Travel
3
2
5
4
258443-A
1 Electrode Holder
Choose correct electrode holder for the
process.
2 Air Stream
The air stream should be in line with the
electrode and positioned between the
electrode and the workpiece.
3 Carbon Electrode
Choose the correct electrode size for the
desired gouge.
4 Gouging Arc
Keep the arc short.
5
Workpiece
Start air compressor and adjust regulator
to correct setting. Use the lowest air
pressure that will blow away the molten
metal. Ensure that the electrode point is
shaped correctly and insert it in the
electrode holder. The electrode should
extend no more than 7 in. (178 mm) and no
less than 2 in. (51 mm) from the electrode
holder. Strike the arc, then open the air
valve. Use proper arc and travel speed to
create the desired shape and condition of
the gouge.
Always cut away from the operator as
molten metal sprays some distance from
the workpiece.
Ensure that everyone in the work area is
not in the path of the spray.
Remove all combustible material from the
work area. Place metal deflection plates in
front of the operation.
6-6. Restoring Factory Defaults
A factory reset of the power source can be accomplished by pressing the Stick and TIG buttons simultaneously for more than four seconds.
The display will show fSt and then go to dashes when the reset is complete.
6-7. Viewing Software Revision
Press and hold the Electrode and In Use buttons simultaneously to view the system software revision level.
While still holding down the Electrode push button, press the In Use push button again to display the User Interface software revision level.
OM-263657 Page 30
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. 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
7-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 255179-B
OM-263657 Page 31
7-3. Welding Power Source And Remote Diagnostics Help Codes
H
0
1
Display Example
Display Code
Fault
H01
Primary Transformer Over Current
Indicates a malfunction in the primary power circuit.
H02
Secondary Thermistor Malfunction
Indicates the left side thermal protection circuitry is
malfunctioning.
H03
Secondary Circuit Over Temperature
H04
Primary Temperature Sensor Malfunction
H05
Primary Circuit Over Temperature
H06
Current Foldback
H08
Output Over Voltage Malfunction
Description
Indicates left side of unit has overheated. Unit has shutdown to
allow fans to lower left side temperature. Operation will continue
after unit is within normal temperature range.
Indicates the right side thermal protection circuitry is
malfunctioning.
Indicates right side of unit has overheated. Unit has shutdown
to allow fans to lower right side temperature. Operation will
continue after unit is within normal temperature range.
Indicates operation at maximum input current..
Output voltage exceeded 100 VDC for more than 1/2 second.
H12
Precharge Incomplete
H13
Internal Voltage Malfunction
Precharge did not complete in allotted time.
H16
PC2 Temperature Sensor Malfunction
H17
PC2 Over Temperature
H18
PC3 Temperature Sensor Malfunction
H19
PC3 Over Temperature
Indicates PC3 has overheated. Unit has shutdown to allow fans
to lower temperature.
H20
PC2 Power Supply Low
Indicates the control supply on PC2 is malfunctioning.
H21
Primary Input Line Voltage Malfunction
H22
Boost Fault
H26
Button Stuck On Power Source
System cannot measure output voltage.
Indicates thermal protection circuitry on the Process Control
board is malfunctioning.
Indicates PC2 has overheated. Unit has shutdown to allow fans
to lower temperature.
Indicates thermal protection circuitry on the System Power
board is malfunctioning.
Indicates input primary line voltage is too low.
Primary line voltage must be at least 90% of specified nominal
voltage.
Indicates the boost circuitry on the right side of unit is
malfunctioning.
Indicates button is stuck on the power source upon start up.
Fault will clear when button is released.
H27
Polarity Switch Fault
H30
Stuck Contactor TIG/Stick
Indicates a stuck remote contactor in either Stick or TIG process.
H32
Accessory Temperature Sensor Malfunction
Indicates the thermistor in the attached FieldPro accessory is
malfunctioning.
H33
Accessory Over Temperature
H96
PC7 Communication Malfunction
Indicates internal communication malfunction to PC7.
H97
PC1 Communication Malfunction
Indicates internal communication from primary power circuitry
to secondary power circuitry on PC1.
H98
Serial Communication Loss
Indicates serial communication was initially made and is now
malfunctioning. May appear normally during firmware updates.
Communication between PC1 and PC5 malfunction.
H99
Serial Communication Malfunction
Indicates serial communication is malfunctioning. May appear
normally during firmware updates. Communication between
PC1 and PC5 malfunction.
OM-263657 Page 32
Indicates the relay circuitry (W1, W2) is malfunctioning.
Indicates the attached FieldPro accessory has overheated.
7-4. Feeder Diagnostics Help Codes
The FieldPro Feeder does not display the same help codes as the power source. Error conditions are indicated by a “HLP” message on the display, or
by the blinking of the Red LED on motor board PC1. To view the Red LED, turn off the power source, remove the wrapper, and turn power source back
on. The Red LED blinks in a 2.5 second cycle. The number of blinks in this period indicates the type of error. If an error condition does not exist on the
motor board, the Red LED is on steady.
H
0
1
Display Example
Display
Code
Red LED On PC1
H11
1 Blink
H12
2 Blinks
Fault
Description
Communication Error
This error occurs 2.5 seconds after a loss
of communication between the motor
board and meter board. The operator may
continue to weld with this error present.
The error may be cleared by turning the
power off, waiting a minimum of 2 seconds,
and turning power back on.
Trigger Error
This error occurs if the operator has fed
approximately 35 ft (10.7 m) of wire without
striking an arc, or if the welding wire is
shorted during a welding operation and
switch DIP4 on the front panel board is depressed toward the OPEN position. The
error may be cleared by releasing the gun
trigger.
H14
4 Blinks (Constant Blinking)
Motor Overload
Indicates that the motor has been drawing
too much current for too long. To remedy,
reduce the wire feed speed or the wire
feeder torque load/duty cycle. The error
may be cleared by turning the power off,
waiting a minimum of 2 seconds, and turning the power back on.
H15
3 Blinks
Bus Bar Overheating
Indicates the arc is drawing too much current for too long. To remedy, reduce the
weld amperage or duty cycle.
7-5. Troubleshooting Welding Power Source
Trouble
No weld output; unit completely in−operative
Remedy
Place line disconnect switch in On position (see Section 5-5).
Check and replace line fuse(s), if necessary*.
Check for proper input power connections (see Section 5-5).
No weld output; meter display On.
Check, repair, or replace RHC-14 remote control.
Unit overheated. Allow unit to cool with fan ON (see Section 4-3).
Check ammeter help displays.
Erratic of improper weld output.
Use proper size and type of weld cable.
Clean and tighten all weld connections.
Check volt sense lead. Straighten any coiled cables.
When remote control is connected to unit output Check RHC-14 remote control switch and potentiometer resistances.
is always on.
*Have a trained and qualified service technician check and replace line fuse(s).
OM-263657 Page 33
7-6. Troubleshooting Welding Power Source Issues
If the welding power source is NOT responding after everything is connected, follow the items listed below before contacting the nearest
factory-authorized service agent:
Welding power source is plugged in and there is no power after turning on unit.
S
If unit is directly connected to a line disconnect box or plugged into a receptacle from a line disconnect box, be sure that the line disconnect switch
or main breaker is in the ON position.
Weld is not consistent from one welding application to another.
S
Be sure that work clamp is connected to a clean, paint-free area of pipe; otherwise, grind an area if necessary to make a good work connection.
S
Keep work clamp as close as possible to joint being welded.
S
Follow recommended settings in Operation section of manual to select a starting point for welding.
S
Recommended joint preparation and fit-up is 1/32-1/16 in (0.8-1.6 mm) land and a 1/8 in (3.2 mm) root opening.
Porosity in weld bead (TIG welding).
S
Check shielding gas supply that there is enough gas and supply is turned on.
S
Check shielding gas flow rate at regulator.
S
Check that gas pressure does not exceed 90 psi (621 kPa).
S
Check all shielding gas fitting and tighten if necessary.
S
Shield joint from wind.
FieldPro Remote does not turn on.
S
Check work sense lead connection. Be sure that the clamp is connected to a clean, paint-free area of the workpiece.
7-7. Power Source Calibration Procedure
. At any point during voltage or amperage calibration, the IN USE button may be used to advance without saving the calibration. This may be useful
when only wishing to verify calibration and not change the settings. Press the ELECTRODE button at any point to exit calibration mode. Routine
calibration is not necessary for most applications, calibration is verified at the factory.
Required Equipment:
Calibrated voltage meter and ammeter
Load bank or shorting cable
Setup And Enter Calibration Mode:
1. Disconnect output cables including all accessories.
2. Turn power on.
3. To enter calibration mode, press and hold the STICK and IN USE buttons at the same time for 2 seconds. Display will show — — —
4. Release buttons. Display will show CAL. Output will be de-energized. Voltage and current meters should measure zero.
S
For Voltage Calibration, connect voltage meter across the output studs. + to ELECTRODE and − to WORK (open circuit load).
S
For Amperage Calibration, connect shorting cable or load bank at heavy load setting to output studs. Connect ammeter to measure output current.
. If at any point the display reading is out of the allowed range, unit may need to have the calibration values defaulted. See below for default procedure. If defaulting the calibration does not resolve the issue, the unit may require servicing.
. If at any point the measured voltage or amperage readings are out of the allowed range or are not the correct polarity (+ or −), the unit may require
servicing.
Voltage Calibration Procedure:
1. When in calibration mode, open/disconnect load from output studs, then press the TIG button.
2. Verify the display shows 27.0 (±2.0).
3. Verify the voltmeter displays -27.0 (±2.0). Verify value is negative.
4. Using the − and + buttons, adjust the display to match the measured value.
5. Wait a few seconds, then verify display and voltmeter reading are the same.
6. Press the TIG button to save the calibration setting.
7. Verify the display shows 72.0 (±5.0), indicating open circuit voltage.
8. Verify the voltmeter displays -72.0 (±5.0). Verify value is negative.
9. Using the − and + buttons, adjust the display to match the measured value.
10. Wait a few seconds, then verify display and voltmeter reading are the same.
11. Press the TIG button to save the calibration setting.
12. Verify the display shows 27.0 (±2.0).
13. Verify the voltmeter displays 27.0 (±2.0). Verify value is positive.
14. Using the − and + buttons, adjust the display to match the measured value.
15. Wait a few seconds, then verify display and voltmeter reading are the same.
16. Press the TIG button to save the calibration setting.
17. Verify the display shows 72.0 (±5.0), indicating open circuit voltage.
18. Verify the voltmeter displays 72.0 (±5.0). Verify value is positive.
OM-263657 Page 34
19. Using the − and + buttons, adjust the display to match the measured value.
20. Wait a few seconds, then verify display and voltmeter reading are the same.
21. Press the TIG button to save the calibration setting.
22. Press ELECTRODE button to exit calibration mode or continue on to Amperage Calibration procedure.
Amperage Calibration Procedure:
1. When in calibration mode, connecting shorting cable/load bank across output studs, then press the STICK button.
2. Verify the display shows 50 (±5.0).
3. Verify the ammeter displays 50 (±5.0).
4. Using the − and + buttons, adjust the display to match the measured value.
5. Wait a few seconds, then verify display and ammeter reading are the same.
6. Press the STICK button to save the calibration setting.
7. Verify the display shows 350 (±5.0).
8. Verify the ammeter displays 350 (±5.0).
9. Using the − and + buttons, adjust the display to match the measured value.
10. Wait a few seconds, then verify display and ammeter reading are the same.
11. Press the STICK button to save the calibration setting.
12. Press ELECTRODE button to exit calibration mode.
Default Calibration Procedure:
S
Three levels of calibration default are provided as follows:
Default all
Default voltage calibration
Default amperage calibration
S
Enter calibration mode using the method described above.
S
Default all
When in calibration mode, press and hold the STICK and TIG buttons at the same time until the display shows — — —
S
Default voltage calibration
When in calibration mode, enter the voltage calibration mode by pressing the TIG button. Then press and hold the STICK and TIG buttons at the
same time until the display shows — — —
S
Default amperage calibration
When in calibration mode, enter amperage calibration mode by pressing the STICK button. Then press and hold the STICK and TIG buttons at
the same time until the display shows — — —
7-8. Updating Software In Welding Power Source
1
SD Card
Insert SD card into the SD card slot
on the front of the unit. Turn power
on or cycle power to the welding
power source. Unit automatically
updates.
The update may take 20 to 30 seconds. The front panel display may
show dashes and/or H99.
Upon completion of the update, the
display shows Crd. Remove SD
card to resume normal operation.
Press and hold the Electrode and In
Use push buttons simultaneously
to verify unit has updated successfully with the correct system software revision level.
1
266872
OM-263657 Page 35
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Welding Power Source Circuit Diagram
OM-263657 Page 36
269202-C
OM-263657 Page 37
255132-B
Figure 8-2. Remote Circuit Diagram
OM-263657 Page 38
229895
Notes
MATERIAL THICKNESS GAUGE
OM-263657 Page 39
OM-263657 Page 40
2
76
4
22
24
25
7
9
3
21
23
26
7
10
29
30
20
5
84 28
27
85
87
6
11
32
8
84
Figure 9-1. Welding Power Source Parts Assembly
79
1
80
15
35
77
7 12 13 14
19
83
7 20
18
33
31
74
16
34
48
82
53
65
36
47
79
75
50
55
56
52
51
46
89
49
73
81
40
66
37 38
45
54
58
73
70
67
56
62
64
44
42
78
59
68
71
60
28 41
39
86
57
72
26
43
69
88
65
61
80
47
74
63
SECTION 9 − PARTS LIST
. Hardware is common and
not available unless listed.
255178-E
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
907633
Description
Figure 9-1. Welding Power Source Parts Assembly
. . . 1 . . . . . . . . . . . . . . . . 257114
. . . 2 . . . . . . . . . . . . . . . 265434
. . . 3 . . . . . . . . . . . . . . . 175138
. . . 4 . . . . . . . . . . . . . . . 170391
. . . 5 . . . . . . . . . . . . . . . 254891
. . . 6 . . . . . . . . . . . . . . . 252839
. . . 7 . . . . . . . . . . . . . . . 268639
. . . . . . . . . . . . . . . . . . . . . 257995
. . . . . . . . . . . . . . . . . . . . . 250037
. . . . . . . . . . . . . . . . . . . . . 250039
. . . . . . . . . . . . . . . . . . . . . 185714
. . . . . . . . . . . . . . . . . . . . . 185717
. . . . . . . . . . . . . . . . . . . . . 185718
. . . . . . . . . . . . . . . . . . . . . 186228
. . . 8 . . . . . C6 . . . . . 264077
. . . 9 . . . . . . . . . . . . . . . 254892
. . . 10 . . . . . . . . . . . . . . . 234344
. . . 11 . . . . . PC4 . . . . . 244477
. . . 12 . . . . . PC6 . . . . . 268280
. . . 13 . . . . . FM1 . . . . . 224694
. . . 14 . . . . . . . . . . . . . . . 176226
. . . 15 . . . . . . S1 . . . . . 244920
. . . . . . . . . . . . . . . . . . . . . 253664
. . . 16 . . . . . . . . . . . . . . . 225097
. . . 17 . . . . . . . . . . . . . . . . 211503
. . . 18 . . . . . . T1 . . . . . . 212132
. . . 19 . . . . . . L3 . . . . . . 272893
. . . 20 . . . . . . . . . . . . . . . 212207
. . . 21 . . . . . . . . . . . . . . . 196355
. . . 22 . . . . D1,D2 . . . . 201531
. . . 23 . . . . . . . . . . . . . . . 199840
. . . 24 . . . . R3/C4 . . . . 233052
. . . 25 . . . . . SR1 . . . . . 201530
. . . 26 . . . RT1,RT2 . . . 199798
. . . 27 . . . . . HD1 . . . . . 182918
. . . 28 . . . . . . . . . . . . . . . 179276
. . . 29 . . . . . . . . . . . . . . . 170647
. . . 30 . . . . . CR1 . . . . . 198549
. . . 31 . . . . . PC7 . . . . . 255714
. . . 32 . . . . . . . . . . . . . . . 252923
. . . 33 . . . . . . . . . . . . . . . 010546
. . . 34 . . . . . . L4 . . . . . . 218020
. . . 35 . . . . . . . . . . . . . . . 227746
. . . 36 . . . . . . . . . . . . . . . 196330
. . . 37 . . . . . . L2 . . . . . . 218018
. . . 38 . . . . . . . . . . . . . . . 218566
. . . 39 . . . . . . . . . . . . . . . 212206
. . . 40 . . . . MOD1, . . . . . . . . . . . .
MOD2 . . . . 261556
. . . 41 . . . . . . . . . . . . . . . 153403
. . . 42 . . . . . . . . . . . . . . . 219472
. . . 43 . . . . . C15 . . . . . 196143
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nameplate/Switch Membrane, Front Pnl . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conn, Circ MS Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plate, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rcpt Assy, Tw Lk Insul Fem(Dinse Type) (Including)2
. . . . Rcpt, Tw Lk Insul Fem Dinse Style w/O-ring . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Tooth 22MMID x 31.5MMOD . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, M20−1.5 1.00 Hex .19H Brs Locking . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O−Ring, 0.989 ID x 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O−Ring, 0.739 ID x 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Door, SD Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, SD Card Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, SD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, FC Source Remote Interface (CE) . . . . . . . . . . . . . . .
. . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, On−Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Heat Sink, Rect LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Xfmr, HF Litz/Litz w/Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Diode Fast Recovery Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Thermistor, NTC 30k ohm @ 25 Deg C 18.00 in. 2500V . . . . . . . . . . . .
. . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . Bushing, Snap−In Nyl 1.000 ID X 1.375 Mtg Hole Cent . . . . . . . . . . . . . .
. . Bushing, Snap−In Nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . Relay, Encl 24VDC SPST 35A/300VAC 4pin Flange Mtg . . . . . . . . . . .
. . Circuit Card Assy, WCC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg WCC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Snap−In Nyl .375 ID X .500 Mtg Hole . . . . . . . . . . . . . . . . . . .
. . Inductor, Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Gasket, Inductor Mounting E55 Ferrite Core . . . . . . . . . . . . . . . . . . . . . . .
. . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Inductor, Pre−Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Gasket, Inductor Mounting E70 Ferrite Core . . . . . . . . . . . . . . . . . . . . . . .
. . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
2
1
1
2
1
3
1
1
1
1
1
1
1
1
1
1
1
..
..
..
..
1
2
1
1
Kit, Input/Pre−regulator And Invertor Module . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Snap−In Nyl .750 ID X 1.000 Mtg Hole Cent . . . . . . . . . . . . . .
Bracket, Mtg Capacitor Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Polyp Met Film 16. uf 400 VDC 10% . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-263657 Page 41
Quantity
Item
No.
. . . 44
. . . 45
. . . 46
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
47
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
Dia.
Mkgs.
Part
No.
Model
Description
907633
Figure 9-1. Welding Power Source Parts Assembly
(Continued)
. . . . . PC2 . . . . . 260280 . . Circuit Card Assy, Interconnect W/Label And Clips . . . . . . . . . . . . . . . . . 1
. . . . . . L1 . . . . . . 212091 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . RM1,
PLG26 . . . . 205751 . . Module, Power Resistor W/Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . +252842 . . Panel, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . +268254 . . Panel, Side Red−D−Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 257258 . . Bracket Upper, Mtg Capacitor/PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PC1 . . . . . 273372 . . Kit, Fieldpro 350 Pc1 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 257260 . . Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . C12,C13 . . . 245614 . . Capacitor, Elctlt 1800 uf 500 VDC Can 2.52 Dia . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 217040 . . Nut, Nylon M12 Thread Capacitor Mounting . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . FM2 . . . . . 183918 . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 252855 . . Bracket, Mtg Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . W1,W2 . . . 247571 . . Contactor, Latching (W1 front, W2 rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 254967 . . Bus Bar, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 254968 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . PC3 . . . . . 252949 . . Circuit Card Assy, Autoline Cntrl Power 70W Potted . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 257115 . . Panel,Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 234126 . . Nut, Conduit 1.000 Npsm Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 215980 . . Bushing, Strain Relief .709/.984 ID x 1.375 Mtg Hole . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 252930 . . Insulator, Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 257239 . . Cable, Power 7.5 ft 8 ga 4c (Non−Stripped End) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . +252841 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . +268255 . . Cover, Top Red−D−Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 256025 . . Insulator, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . CT1 . . . . . 253320 . . Xfmr, Current Sensing 200/1 W/15 in. Leads . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 219471 . . Bracket, Mtg Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 265141 . . Circuit Card Assy, Input Filter FieldPro . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 148025 . . Lug,univ W/scr 600V 2/0-6 wire .266 stud . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . 219473 . . Bracket,Mtg CE Filter Ground Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . 257044 . . Bracket, Top Extruded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . 257047 . . Handle, Carrying Pwxfld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 257049 . . Handle, Formed Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 257045 . . Bracket, Side Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . 257043 . . Bracket, Base Extruded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . PC5 . . . . . 265964 . . Circuit Card Assy, Frnt Pnl Pwxfld Ps/Rmt w/Pgm VRD . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 257259 . . Bracket Lower, Mtg Capacitor/PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 257382 . . Bracket, Capacitor Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 257048 . . Handle, Formed Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 147139 . . Tape, Adh Acrylic Double Sided .010 x .500 x 3.000 . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . 257050 . . Bearing, Handle Pwxfld Ps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . 233397 . . Insulator, Board Bracket Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 191944 . . Capacitor,Polyp Met Film 10. Uf 250 Vac 10% . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 194254 . . Core,Toroidal 22.25mm Id X 36.96mm Od X 15.88mm Th . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 259715 . . Core, Toroidal 28.7mm ID x 43.1mm OD x 18.5mm Th . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 241027 . . Core, Toroidal .748 ID x 1.142 OD x .600 Thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 224262 . . Core, Toroidal Nanocrystalline (43.1mm Diameter) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 131447 . . Core, Toroidal 1.332 ID x 1.932 OD x .625 Thk . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 255736 . . Core, Ferrite Emi Snap-on .393 ID x .877 OD x 1.250 thk . . . . . . . . . . . 3
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS
OM-263657 Page 42
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
907633
Description
Figure 9-1. Welding Power Source Parts Assembly
(Continued)
. . . . . PLG51,PLG118,
PLG72,
PLG117 . . . 255063
. . . . . . . . . . PLG73 . . . . 256953
. . . . . . . . . . PLG21 . . . . . 115091
. . . . . . PLG14,PLG34,
PLG23 . . . . . 115092
. . . . . . . . . PLG32,
PLG115 . . . . 115094
. . . . . . . . . PLG33,
PLG14 . . . . 130203
. . . . . . PLG13,PLG35,
PLG2/RC2 . . 131054
. . . . . . . . . . PLG12 . . . . 131056
. . . . . . . . . . PLG11 . . . . 131204
. . . . . . . . RC3/PLG3 . . 135635
. . . . . . PLG111,PLG22,
PLG31,
PLG113 . . . 201665
. . . . . . . . . . . . . . . . . . . . . 227927
. . . . . . . . . . . . . . . . . . . . . 212073
. . . . . . . . . . . . . . . . . . . . . 179310
. . . . . . . . . . . . . . . . . . . . . 179309
. . . . . . . . . . . . . . . . . . . . . 212945
. . . . . . . . . . . . . . . . . . . . . 219335
. . . . . . . . . . . . . . . . . . . . . 121389
. . . . . . . . . . . . . . . . . . . . . 194017
. . . . . . . . . . . . . . . . . . . . . 194016
. . . . . . . . . . . . . . . . . . . . . 155436
. . . . . . . . . . . . . . . . . . . . . 252846
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
..
..
..
..
Housing
Housing
Housing
Housing
Plug+Skts,
Plug+Skts,
Plug+Skts,
Plug+Skts,
(Service
(Service
(Service
(Service
Kit)
Kit)
Kit)
Kit)
.................................
.................................
.................................
.................................
3
1
1
1
..
..
..
..
..
..
..
..
..
..
..
..
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock/Exploding Parts-wdles . . . . . . . . . . . . . . .
Label, Warning Exploding Parts Can CE Wordless . . . . . . . . . . . . . . . . . .
Label, General Precautionary Wordless Intl Small . . . . . . . . . . . . . . . . . .
Label, Warning Falling Equipment Can Injure-wordles . . . . . . . . . . . . . . .
Label,Warning Incorrect Connections Ce Wordless . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock Can Kill Wordless(CE) . . . . . . . . . . . . . . .
Label, Miller 12.437 x 5.250 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Work (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Electrode (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ckt, Pipeworx 350 FieldPro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1
2
2
2
1
1
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-263657 Page 43
. Hardware is common and
not available unless listed.
8
10
16
3
1
14
15
12
6
15
16
2
11
7
17
5
19
18
9
13
4
255407-B
Figure 9-2. Remote Parts Assembly
OM-263657 Page 44
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
301176
Description
Figure 9-2. Remote Parts Assembly
. . . 1 . . . . . . . . . . . . . . +253680
. . . 2 . . . . . . . . . . . . . . . 253723
. . . 3 . . . . . . . . . . . . . . . 253372
. . . 4 . . . . . . . . . . . . . . . 253671
. . . 5 . . . . . . . . . . . . . . . 253666
. . . 6 . . . . . HD1 . . . . . 191941
. . . 7 . . . . . . . . . . . . . . . 255046
. . . 8 . . . . . . . . . . . . . . . 255045
. . . 9 . . . . . . . . . . . . . . . 242239
. . . 10 . . . . . . . . . . . . . . . 242240
. . . 11 . . . . . PC1 . . . . . 255721
. . . 12 . . . . . . . . . . . . . . . 026947
. . . 13 . . . . . . . . . . . . . . . 254969
. . . 14 . . . . . . . . . . . . . . . 254883
. . . . . . . . . . . . . . . . . . . . . 255326
. . . . . . . . . . . . . . . . . . . . . 214521
. . . . . . . . . . . . . . . . . . . . . 255253
. . . . . . . . . PLG12,
PLG21,
PLG14 . . . . 255063
. . . 15 . . . . . . . . . . . . . . . 121276
. . . 16 . . . . . . . . . . . . . . . 254257
. . . 17 . . . . . . . . . . . . . . . 258463
. . . 18 . . . . . . . . . . . . . . . 265458
. . . 19 . . . . . . . . . . . . . . . 265964
. . . . . . . . . . . . . . . . . . . . . 255133
. . . . . . . . . . . . . . . . . . . . . 255145
. . . . . . . . . . . . . . . . . . . . . 255326
. . . . . . . . . . . . . . . . . . . . . 255259
. . . . . . . . . . . . . . . . . . . . . 258410
. . Case, Molded (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Base, Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pouch, Nylon 1000 Denier W/Velcro . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Gasket, Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bus Bar, LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Transducer, Current 200A Module Supply V+/− 15V . . . . . . . . . . . . . . . .
. . Insert, Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Volt Sense 15 ft w/Clamp & Term . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conn, Tw Lk Insul Male(Dinse Type)1/0-2/0 Blk1
. . Conn, Tw Lk Insul Fem (Dinse Type) 1/0-2/0 Blk1
. . Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand−Off, Insul .250−20 x 1.000 Lg x .312 Thd . . . . . . . . . . . . . . . . . . . .
. . Stand−Off, No 6−32 x 1.375 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . .
. . Stud, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, PipeWorx 350 Field Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Turn Off Power Before Opening . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Disconnect Input Power Before Servicing . . . . . . . . . . . .
1
1
1
1
1
1
2
1
..
..
..
..
..
..
..
..
..
..
..
3
2
2
4
1
1
1
1
1
1
1
Housing Plug + Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Strain Relief .450/.709 ID x 1.115 Mtg Hol . . . . . . . . . . . . . . . . .
Lead List, Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, Nylon 010-32 x 2.500 x .500 Hex . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate/Switch Membrane, Front Pnl Pwxfld Rmt (CE) . . . . . . . . . . .
Circuit Card Assy, Frnt Pnl Pwxfld Ps/Rmt w/Pgm VRD . . . . . . . . . . . . .
Plugs, w/Leads (User Interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, LEM Pipeworx 350 Field Remote . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Nameplate Pipeworx 350 Field Remote . . . . . . . . . . . . . . . . . . . . .
Label, Notice Only FieldPro Compatible . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card, Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-263657 Page 45
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2017
(Equipment with a serial number preface of MH or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective date of
6.
90
Days — Parts
this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
* Canvas Covers
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
* Induction Heating Coils and Blankets, Cables, and
FITNESS.
Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any
* M-Guns
warranted parts or components that fail due to such defects in material
* MIG Guns, Subarc (SAW) Torches, and External
or workmanship. Miller must be notified in writing within thirty (30) days
Cladding Heads
of such defect or failure, at which time Miller will provide instructions on
*
Remote Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted
* Replacement Parts (No labor)
as an online warranty claim, the claim must include a detailed
* Spoolmate Spoolguns
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.
Miller’s True Blue® Limited Warranty shall not apply to:
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.
1.
2.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2017-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2017 Miller Electric Mfg. Co.
2017−01
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