Miller | MB230978U | Owner Manual | Miller SUBARC AC/DC/ 1000/1250 CE AND NON-CE User manual

Miller SUBARC AC/DC/ 1000/1250 CE AND NON-CE User manual
OM-246 011A
2011−05
Processes
Submerged (SAW) Welding
Description
Arc Welding Power Source
Sub Arc AC/DC 1000/1250
CE And Non-CE
File: Submerged (SAW)
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Insert Latest D of C 246 165-A
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. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Weld Output Terminals and Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Terminal Strip TE1, TE2 and Remote 14 Receptacle RC7 Information . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Basic Sub Arc (SAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. 115 Volts AC Receptacle And Circuit Breaker 460 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. 230 Volts AC Receptacle And Circuit Breakers (400 Volt Input Models) . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Matching Primary Lines L1, L2, And L3 When Using Multiple AC Units . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAKING WELD OUTPUT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Work And Electrode Cable Connections For Single DC or AC Arcs . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Connecting Multiple Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Using AC Arcs Terminal Strip TE1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls For Non-CE Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Front Panel Controls For CE Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Access Area Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−01
7
Protect yourself and others from injury — read and follow these precautions.
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.
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 for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
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 and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
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.
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-246 011 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.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
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 protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
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 closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-246 011 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments 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.
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.
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.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
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.
ARC WELDING can cause interference.
MOVING PARTS can injure.
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.
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.
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-246 011 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.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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,
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).
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, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or 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-246 011 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_2011−01
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
D
D
D
D
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
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.
OM-246 011 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
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 Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
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.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
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 intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
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 des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-244 011 Page 6
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 (voir les normes de sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
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 Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
OM-246 011 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
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.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
OM-244 011 Page 8
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global
Engineering Documents (téléphone : 1-877-413-5184, site internet :
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : 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, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
Internet : www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
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 de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
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.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-246 011 Page 9
OM-244 011 Page 10
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
1
2
1
3
2
3
4
5
6
5
4
7
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Overuse can cause
overheating. Follow rated duty
cycle.
Disconnect input plug or
power before working on
machine.
Become trained and read the
instructions before working on
the machine.
Connect green or
green/yellow grounding
conductor to ground terminal.
Connect input conductors (L1,
L2 And L3) to line terminals.
2
3
? V
? A
252157-A
3
3
7
6
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1
2
2
3
3
4
4
glk s;dglk
fgk
ks;ld
;lg
sdlks;ldfgks;dglk
kds;lgks;ldfgk
s;dglk
gk
ds;lgk s;ldfgk
s;d
Aslg fsgk Aslgkds
Asl dh
S;ldkgsld
V
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Turn power off before
connecting to 115 volt
receptacle.
Read the Owner’s Manual
115 V
194557-A
OM-246 011 Page 11
3-2. Symbol Definitions
. Some symbols are found only on CE products.
A
Amperage
V
Voltage
Hz
Hertz
Direct Current
(DC)
Alternating Current
(AC)
Panel/Local
Line Connection
Three Phase
Output
On
Voltage Input
Off
Submerged Arc
Welding (SAW)
Read Operator’s
Manual
Remote
Percent
U2
Conventional Load
Voltage
I1eff
Maximum Effective
Supply Current
U0
I2
Rated No-Load
Voltage (Average)
U1
X
Duty Cycle
Circuit Breaker
(Supplementary
Protector)
Rated Supply
Voltage
I1max
Rated Welding
Current
Protective Earth
(Ground)
3-Phase Power
Source With
AC/DC Output
Temperature
Ventilating And Air
Circulating Fan
Degree Of
Protection
Positive
Negative
Fuse
Single Phase
Caution
Work Connection
Electrode Connection
Frame Or Chassis
Increase/Decrease
IP
TE
Rated Maximum
Supply Current
Terminal Strip
3-3. WEEE Label (For Products Sold Within The EU)
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
OM-246 011 Page 12
SECTION 4 − INSTALLATION
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
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 may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
IEC/TS 61000−3−4 may be used to guide the parties concerned by the installation of arc welding equipment with an input current above 75 Amps
in a low-voltage network.
ce-emc 5 2010-10
4-2. Serial Number And Rating Label Location
The rating information for the power source is located on the front or the rear of the machine. Use the rating labels to determine input power requirements and/or rated output. The serial number is located on the front of the machine, for future reference, write serial number in space provided on
back cover of this manual.
4-3. Specifications
AC or DC
Rated Output
1000 A at 44 V,
100% Duty Cycle;
1250 A at 44 V,
60% Duty Cycle
Voltage
Range in
CV Mode
Amperage
Range in
CC Mode
Max. OpenCircuit
Voltage
25−44 V
300−1250 A
71 V
25−44 V
300−1250 A
71 V
RMS Amps Input at Rated Load
Output, 3-Phase at NEMA Load
Voltages and Class I Rating
IP
Rating
380 V
(50 Hz)
400V
(50 Hz)
460 V
(60 Hz)
KVA
KW
IP21
140
(3*)
141
(3*)
122
(3*)
98
(2.37*)
53
(0.95*)
179
(3*)
176
(3*)
158
(3*)
122
(2.37*)
67
(0.95*)
*While idling
OM-246 011 Page 13
4-4. Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
100% Duty Cycle At 1000 Amperes
If unit overheats, high temperature
shutdown light turns On, thermostat(s) opens, output stops, and
cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.
Continuous Welding
Overheating
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 181 560
4-5. Dimensions And Weight
A
Dimensions
Height* 44 in. (1118 mm)
Width*
27-1/4 in. (692 mm)
Depth*
46 in. (1168 mm)
A
1-7/8 in. (48 mm)
B
44-1/8 in. (1120 mm)
C
11/16 in. (17 mm)
D
26-1/16 in. (662 mm)
E
4 holes:
21/32 in. (6.5 mm) dia
Weight
1180 lb (535 kg)
B
E
Front
C
D
* Includes lifting eye, handles, hardware, etc.
OM-246 011 Page 14
4-6. Selecting a Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
Movement
3
Line Disconnect Device
Locate unit near correct input
power supply.
!
1
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
OR
2
Location
3
18 in.
(460 mm)
18 in.
(460 mm)
247 475-B
OM-246 011 Page 15
4-7. Weld Output Terminals and Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
30 m (100 ft) or Less
Work
Weld Output
Terminals
Requires cable lugs with
1/2 in. diameter holes.
70 m
(250 ft)
90 m
(300 ft)
105 m
(350 ft)
120 m
(400 ft)
60 − 100%
Duty
Cycle
mm2 (AWG)
mm2 (AWG)
100
20 (4)
20 (4)
20 (4)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
150
30 (3)
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
200
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
120 (4/0)
250
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x70
(2 ea. 2/0) (2 ea. 2/0)
300
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x95
2x95
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 3/0)
350
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x95
2x95
2x120
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 3/0) (2 ea. 4/0)
400
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x95
2x120
2x120
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 4/0) (2 ea. 4/0)
500
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x95
2x120
3x95
3x95
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 4/0) (3 ea. 3/0) (3 ea. 3/0)
600
95 (3/0)
120 (4/0)
2x70
2x95
2x120
3x95
3x120
3x120
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 4/0) (3 ea. 3/0) (3 ea. 4/0) (3 ea. 4/0)
700
120 (4/0)
2x70
(2 ea. 2/0)
2x95
2x120
3x95
3x120
3x120
4x120
(2 ea. 3/0) (2 ea. 4/0) (3 ea. 3/0) (3 ea. 4/0) (3 ea. 4/0) (4 ea. 4/0)
800
120 (4/0)
2x70
(2 ea. 2/0)
2x95
2x120
3x120
3x120
4x120
4x120
(2 ea. 3/0) (2 ea. 4/0) (3 ea. 4/0) (3 ea. 4/0) (4 ea. 4/0) (4 ea. 4/0)
900
2x70
(2 ea. 2/0)
2x95
(2 ea. 3/0)
2x120
3x95
(2 ea. 4/0) (3 ea. 3/0)
1000
2x70
(2 ea. 2/0)
2x95
(2 ea. 3/0)
2x120
3x95
(2 ea. 4/0) (3 ea. 3/0)
1250
2x95
(2 ea. 3/0)
2x120
(2 ea. 4/0)
3x95
4x95
(3 ea. 3/0) (4 ea. 3/0)
3/4 in.
* This
60 m
(200 ft)
10 − 60%
Duty
Cycle
Welding
Amperes
Electrode
Weld Output
Terminals
45 m
(150 ft)
10 − 100% Duty Cycle
mm2 (AWG)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
OM-246 011 Page 16
Milan Ref. S-0007-G 2009−08
4-8. Connecting Weld Output Cables
4
1
Do not place
anything between
weld cable terminal
and copper bar.
2
3
Correct Installation
Tools Needed:
3/4 in. (19 mm)
!
Turn off power before connecting to
weld output terminals.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
Incorrect Installation
803 778-B
1 Weld Output Terminal
2 Supplied Weld Output Terminal Nut
3 Weld Cable Terminal
4 Copper Bar
Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar. Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
OM-246 011 Page 17
4-9. Terminal Strip TE1, TE2 and Remote 14 Receptacle RC7 Information
24 VOLTS AC
REMOTE OUTPUT CONTROL
115 VOLTS AC
GND
A/V AMPERAGE
VOLTAGE
REMOTE VOLTAGE SENSING
Socket
on RC7
Terminal
on TE2
Terminal
on TE1
Information
A
−
−
24 volts, 12 amperes, AC. Protected by circuit breaker
CB2.
B
−
−
Contact closure to A completes 24 volts AC contactor
control circuit.
C
−
−
Command reference; +10 volts DC.
D
−
−
Remote control circuit common.
E
−
−
0 to +10 volts DC input command signal from remote
control.
I
−
−
115 volts, 12 amperes AC. Protected by circuit breaker
CB1.
J
−
−
Contact closure to I completes 115 volts AC contactor
control circuit.
K
−
−
Chassis common.
G
−
−
Circuit common for 24 and 115 volts AC circuits.
F
−
−
Current feedback; +1 volt DC per 100 amperes.
H
−
−
Voltage feedback; +1 volt DC per 10 output terminal
volts.
*
N
−
Voltage sensing signal from Work weld output terminal.
*
P
−
Voltage sensing signal from Electrode weld output
terminal.
−
TP
−
Test Point
−
−
A
Used for synchronizing multiple AC arcs.
−
−
C
Used for synchronizing multiple AC arcs.
−
−
E
Used for synchronizing multiple AC arcs.
* Not Used, − Not Applicable
!
Turn Off welding power
source before opening access door.
1
2
Access Door
Remote 14 Receptacle
(Mounted Inside Access Area)
Terminal Strip TE2
Terminal Strip TE1
Remote Control
3
4
5
5
Connect remote control to Remote
14 receptacle.
A
1
K
B
C
D
L
2
I
N
H
M
E
4
J
G
F
3
247 476-C
OM-246 011 Page 18
4-10. Basic Sub Arc (SAW) Welding
. Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive assembly cable, drive rolls, gun,
welding wire, weld cables, remote voltage sense leads, and flux system for the desired application.
A. Basic Sub Arc (SAW) Equipment Connections
!
Turn off welding power source and weld control before making connections.
. Use remote voltage sense leads in all applications.
. Suggested size for remote voltage sense wire is 20 - 12 gauge.
. Connect weld cables and voltage sense leads as shown for all polarities.
. When using an RMS meter to measure actual arc voltage (X), first measure ACV measure DCV, then calculate X based on X=
VAC2 + VDC2
second,
Flux System
Sub Arc AC/DC 1000/1250
Flux
Valve
14-Pin Welding
Power Source
Control Cord
HDC Controller
10-Pin Motor
Control Cord
From Terminal Strip
TE2 Terminal N
Wire
Drive
Assembly
Workpiece
Weld Cables
From Terminal
Strip TE2 Terminal P
Use an Amprobe ACDC/3400 IND,
Fluke 345, or Fluke 355 meter only
247 480
247 476-C
OM-246 011 Page 19
B. Remote Voltage Sensing Leads Placement Guidelines For A Single Arc (Required)
Remote Voltage
Sense Leads
Welding Power
Source
BAD
Sense lead is affected by weld
current.
Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.
Work
Clamp
Remote Voltage
Sense Leads
Welding Power
Source
BEST
Sense leads are out of the current
paths.
Sense leads detect arc voltage accurately.
Best starts, arcs and most reliable
results.
Work
Clamp
Ref. 804 108-A
OM-246 011 Page 20
C. Sensing Leads Placement Guidelines For Multiple Arcs
Remote Voltage
Sense Leads
Lead
Welding Power
Source
Trail
Trail
Current flow from lead affects trail
sense.
Current flow from trail affects lead
sense.
Remote Voltage
Sense Leads
Lead
BAD
Neither sense lead picks up the
correct work voltage, causing
starting and welding arc instability.
Welding Power
Source
Work
Clamp
Trail
Lead
Lead
Remote Voltage Sense Leads
Lead
Remote Voltage
Sense Leads
Trail
Work
Clamp
Work
Clamp
Welding Power
Source
BETTER
Lead sense is only affected by
weld current from lead.
Trail sense lead is only affected
by weld current from trail.
Trail
Welding Power
Source
Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.
Lead
Trail
Remote Voltage Sense Leads
Lead
Welding Power
Source
Trail
Trail
Both sense leads are out of the
current paths.
Both sense leads detect arc voltage accurately.
Remote Voltage
Sense Leads
Lead
BEST
Welding Power
Source
No voltage drop between lead and
trail sense.
Best starts, arcs and most reliable
results.
Work
Clamp
Trail
Lead
Ref. 804 108-A
OM-246 011 Page 21
4-11. 115 Volts AC Receptacle And Circuit Breaker 460 Volt Models
1
115 VAC
115 V 15 A AC Receptacle
Power is shared between the duplex receptacle and the 115 volt
output connections and the Remote
14 receptacle (see Section 4-9).
15A
2
1
Supplementary Protector CB1
CB1 protects 115 volts AC receptacle and Remote 14 receptacle
from overload.
2
Ref. 175 086 / 247 477-C
4-12. 230 Volts AC Receptacle And Circuit Breakers (400 Volt Input Models)
1
2
230 V 16 A AC Receptacle
Supplementary Protector CB1
CB1 protects the Remote 14 receptacle from overload.
3
Supplementary Protector CB3
CB3 protects the 230 volts AC receptacle from overload.
1
3
2
Ref. 175 086 / 247 478-C
OM-246 011 Page 22
4-13. Electrical Service Guide
A. 1000 Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
Three-Phase, 60 Hz
Input Voltage (V)
460
Input Amperes (A) At Rated Output
158
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
175
Normal Operating Fuses 3
225
1
Min Input Conductor Size In AWG 4
379 (115)
Max Recommended Input Conductor Length In Feet (Meters)
4
Min Grounding Conductor Size In AWG 4
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
B. 1250 Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
Three-Phase, 50 Hz
Input Voltage (V)
380
400
Input Amperes (A) At Rated Output
179
176
Time-Delay Fuses 2
200
200
Normal Operating Fuses 3
250
250
1/0
1/0
323 (98)
352 (107)
4
4
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-246 011 Page 23
Notes
OM-246 011 Page 24
4-14. Connecting Input Power
= GND/PE Earth Ground
8
7
!
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.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
!
When using multiple units which will be
linked with the synchronizing terminal
strip TE1, ensure that primary input power conductors are connected to each unit
in the same sequence (L1 to L1, L2 to L2,
and L3 to L3.)
10
9
. See Section 4-15 for information on testing
4
L1 (U)
L2 (V)
L3 (W)
6
for proper primary phase sequence.
6
See rating label on unit and check input voltage
available at site.
Open rear panel access door.
1
5
Terminal Block
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 4-13. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage capacity and correct hole size.
1
Welding Power Source Input Power Connections
2
Strain Relief
Route conductors (cord) through strain relief and
tighten screws.
3
4
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding conductor to welding power source grounding terminal first.
5
6
2
Welding Power Source Line Terminals
Input Conductors L1 (U), L2 (V) And L3
(W)
Connect input conductors L1 (U), L2 (V) and L3
(W) to welding power source line terminals.
Close and secure rear panel access door.
Disconnect Device Input Power Connections
7
8
3
Disconnect Device (switch shown in OFF
position)
Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding conductor to disconnect device grounding terminal
first.
4
9
Tools Needed:
7/16 in.
3/8 in.
= GND/ PE Earth Ground
3/16 in.
Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And L3
(W) to disconnect device line terminals.
10 Overcurrent Protection
Select type and size of overcurrent protection using Section 4-13 (fused disconnect switch
shown).
Close and secure door on line disconnect device. Remove lockout/tagout device, and place
switch in the On position.
Ref. 247479-B / 803 766-C
OM-246 011 Page 25
4-15. Matching Primary Lines L1, L2, And L3 When Using Multiple AC Units
!
Set on AC Volts Scale
Meter Polarity Does Not Matter
Only qualified persons
should install, operate,
maintain, and repair this
unit.
This test must be performed on the
units that will be interconnected using the test point (TP) terminal strip
TE2. This refers to the multiple unit
hook-ups shown in Section 5-2.
Turn power On to both units. Use an
AC voltmeter to measure the voltage between terminal TP of terminal strip TE2 on both units as
shown.
If the measured voltage is approximately 0 (zero) volts, the primary
lines are properly phased.
!
Turn off welding power
source and disconnect and
lockout/tagout input power
before changing connections at primary input
contactor.
If the measured voltage is approximately 53 volts, swap the input conductor connections to L1 and L3 on
the primary input contactor of unit
B.
Terminal Strip
TE2
Terminal Strip
TE2
Unit A
(First Unit)
If the measured voltage is approximately 46 volts, swap L1 and L2 on
the primary input contactor of unit
B. The meter will then read either
approximately 53 volts or approximately 26 volts. If the meter reads
approximately 53 volts, swap L1
and L3. If the meter reads approximately 26 volts, swap L2 and L3.
If the measured voltage is approximately 26 volts, swap L1 and L2 on
the primary input contactor of unit
B. The meter will then read either
approximately 0 (zero) volts or
approximately 46 volts. If the meter
reads approximately 0 volts, the primary lines are properly phased. If
the meter reads approximately 46
volts, swap L1 and L2 again, and
swap L2 and L3.
Unit B
(Second Unit)
L1 (U)
L2 (V)
L3 (W)
When the second unit’s primary line
phase sequences are matched with
the first unit, test primary phasing
between third unit (if applicable)
and second unit. Always test and
correct phasing between following
unit and unit previous to it.
Terminal Block
247 476-C / 247 479-B
OM-246 011 Page 26
SECTION 5 − MAKING WELD OUTPUT CONNECTIONS
5-1. Work And Electrode Cable Connections For Single DC or AC Arcs
!
Turn Off welding power
source before opening access
door.
NOTICE − If there are any questions
regarding this procedure, contact the
factory before connecting units.
For AC output:
Connect the proper size and number
of weld output cables (see Section
4-7) to one or more of the welding
power source electrode terminals.
Connect the proper size and number
of ground cables to one or more of the
welding power source work terminals.
To Electrode
Connections
To Work
247 476-C
OM-246 011 Page 27
5-2. Connecting Multiple Units
!
Non-Parallel Connections
To AC Or DC Output
Electrode #1
To AC Output
Electrode #2
Turn Off welding power
source before opening access door.
NOTICE − This procedure is not
for paralleling. Refer to connection below for paralleling procedures Severe damage to units
may occur if units are not correctly
connected for parallel operation.
To use two or more AC arcs with
separate electrodes, make connections as shown.
Set up AC output units according to
Section 5-3.
CC
CV
2
To Next AC Unit
Second Unit (And
Following Units)
To Work
Connections
Shielded Cable To
Terminal Strip TE1
First Unit
Connections
To Work
!
Parallel Connections
To Electrode
Turn Off welding power
source before opening access door.
NOTICE − If there are any questions regarding the paralleling procedure, contact the factory before
connecting units. Severe damage
to units may occur if units are not
correctly connected for parallel
operation.
To use two or more units with one
electrode, make connections as
shown.
1
Set up AC output units according to
Section 5-3.
. The first unit controls voltage.
All remaining units supply additional current.
CC
1
CV
2
2
To Next AC Unit
First Unit
Connections
To Work
Second Unit (And
Following Units)
Connections
CC/CV Switch
NOTICE − All units being paralleled
must be in CC position (see Section
6).
. When running multiple units in
parallel, Parallel Controller
(Miller part number 194711)
must also be used. Install controller according to instructions
provided with unit.
To Work
Shielded Cable To
Terminal Strip TE1
. Although all units are set in the
247 476-C
OM-246 011 Page 28
Power/Balance Control
NOTICE − All units being paralleled
must be set to the same balance
(see Section 6).
CC position, the paralleled process runs in constant voltage.
5-3. Using AC Arcs Terminal Strip TE1 Connections
!
1
Turn Off welding power
source before opening access
door.
. DC output units do not require
synchronization with AC output
units.
Tools Needed:
NOTICE − All units must be set to the
same balance (see Section 6) when
multiple units are connected in AC.
NOTICE − If there are any questions
regarding the paralleling procedure,
contact the factory before connecting
units. Severe damage to units may
occur if units are not correctly connected for parallel operation.
1
Phase Shift
Terminal Strip TE1
This procedure allows the AC output
waveforms of two or more units to
have the correct phase shift. Make
connections between terminal strip
TE1 on applicable AC output units as
shown in illustration.
Waveform 1
. Do not disturb factory connections to terminal strip TE1.
Waveform 2
!
Ensure that primary input
power conductors are connected to each unit in the same
sequence (L1 to L1, L2 to L2,
and L3 to L3). See Section 4-14
for information on connecting
input power. See Section 4-15
for information on testing for
proper primary phase sequence.
2
Lead Being Connected To TE1
AC Waveforms
. Use two-conductor (12 to 20 gauge) with uninsulated ground,
shielded cable to make TE1 connections. Connect uninsulated
ground wire to terminal C on TE1.
1
3/8 in
(10 mm)
Strip 3/8 in. (10 mm) insulation off end
of lead. Press tab in slot with screwdriver or similar device, insert end of
lead into proper location on TE1 and
release tab.
Close and secure access door.
2
Connections from first to second
welding power source:
terminal A to terminal E,
terminal C to terminal C
TE1 on first welding
power source
Connections from second to third
welding power source:
terminal A to terminal E,
terminal C to terminal C
Connections from third to fourth
welding power source:
terminal A to terminal E,
terminal C to terminal C
TE1 on second welding
power source
TE1 on third welding
power source
Repeat same connection sequence on following welding power sources
Terminal Strip TE1 Connections For Running Multiple AC Arcs
Ref. 247 476-C
OM-246 011 Page 29
SECTION 6 − OPERATION
6-1. Front Panel Controls For Non-CE Models
1 Output Control Switch
For weld output, place switch in On position.
For remote control of output, make connections to Remote 14 receptacle (see Section
4-9) and place switch in Remote position.
2 Output On LED
!
Output is on and weld output studs are
energized when LED is lit.
3 A/V (Amperage/Voltage) Control Switch
For front panel control, place switch in Panel
position and use the A/V Adjust control.
!
Turn Off power before connecting remote device.
For remote control, connect remote device to
Remote 14 receptacle, and place switch in
Remote position. Remote control provides full
range of unit output regardless of A/V Adjust
2
4
3
1
5
control setting
4 A/V (Amperage/Voltage) Adjustment
Control
Use control to select weld voltage when CC/
CV switch is in the CV position, or amperage
when CC/CV switch is in the CC position.
Control may be adjusted while welding. Numbers on scale are for reference only.
5 Terminal TE1
To run a single machine in the CC mode, jumper terminal A to E on TE1.
6 Power/Balance Control
Use control to select Direct Current Electrode
Positive (DCEP − EP), or Direct Current Electrode Negative (DCEN − EN), or select one of
the following AC Balance/Frequency combinations: 80/20-18 Hz, 70/30-18 Hz, 67/33-60
Hz, 60/40-18 Hz, 50/50-90 Hz, 50/50-10 Hz,
40/60-18 Hz, 33/67-60 Hz, 30/70-18 Hz, or
20/80- 18 Hz.
7 Power Switch w/Indicator Light
8 High Temperature Shutdown Light
See Section 4-4.
. The
fan motor is thermostatically
controlled and only runs when cooling is
needed.
9 CC/CV Switch
Switch is mounted on electronics baffle.
!
Turn Off welding power source and
disconnect lockout/tagout input
power before removing cover to
change switch position.
Place switch in desired position and install
cover.
6
8
7
CC
CV
9
Ref. 246 002-D / 248 485-B / Ref. 247 476-C
OM-246 011 Page 30
6-2. Front Panel Controls For CE Models
1 Output Control Switch
For weld output, place switch in On position.
For remote control of output, make connections to Remote 14 receptacle (see Section
4-9) and place switch in Remote position.
2 Output On LED
!
Output is on and weld output studs are
energized when LED is lit.
3 A/V (Amperage/Voltage) Control Switch
For front panel control, place switch in Panel
position and use the A/V Adjust control.
!
Turn Off power before connecting remote device.
For remote control, connect remote device to
Remote 14 receptacle, and place switch in
Remote position. Remote control provides full
range of unit output regardless of A/V Adjust
4
3
2
1
5
control setting
4 A/V (Amperage/Voltage) Adjustment
Control
Use control to select weld voltage when CC/
CV switch is in the CV position, or amperage
when CC/CV switch is in the CC position.
Control may be adjusted while welding. Numbers on scale are for reference only.
5 Terminal TE1
To run a single machine in the CC mode, jumper terminal A to E on TE1.
6 Power/Balance Control
Use control to select Direct Current Electrode
Positive (DCEP − EP), or Direct Current Electrode Negative (DCEN − EN), or select one of
the following AC Balance/Frequency combinations: 80/20-15 Hz, 70/30-15 Hz, 67/33-50
Hz, 60/40-15 Hz, 50/50-75 Hz, 50/50-8 Hz,
40/60-15 Hz, 33/67-50 Hz, 30/70-15 Hz, or
20/80- 15 Hz.
7 Power Switch w/Indicator Light
8 High Temperature Shutdown Light
See Section 4-4.
. The
fan motor is thermostatically
controlled and only runs when cooling is
needed.
9 CC/CV Switch
Switch is mounted on electronics baffle.
!
Turn Off welding power source and
disconnect lockout/tagout input
power before removing cover to
change switch position.
Place switch in desired position and install
cover.
6
8
7
CC
CV
9
Ref. 246 334-E / 248 443-C / Ref. 247 476-C
OM-246 011 Page 31
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
!
. Maintain more often
Disconnect input power
before maintaining.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
during severe conditions.
= Repair
l = Replace
Every
3
Months
nl Labels
l Cracked Parts
 l Cracked Cables
Every
3
Months
n lCables And Cords
Every
3
Months
~:Weld Terminals
Every
6
Months
~:Blow out inside
7-2. Fuse F1
!
Turn Off welding power
source and disconnect lockout/tagout input power before checking fuse.
Fuse F1 protect the 115 volt AC
winding of transformer T2. If fuse
F1 opens, the welding power
source shuts down.
Open rear panel access door to access fuses.
1
1
Fuse F1
Check F1 and replace if needed,
using a fuse of the same rating.
Close and secure rear panel access door.
Tools Needed:
3/8 in.
247 479-B
OM-246 011 Page 32
7-3. Access Area Supplementary Protectors
!
Turn Off welding power
source before checking circuit breakers.
1
Supplementary Protector CB2
CB2 protects the 24 VAC portion of
the Remote 14 receptacle.
Press button to reset breaker.
1
CB2
247 476-C
7-4. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-14).
Check fuse F1 and replace if necessary (see Section 7-2).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-14).
Check for proper input power connections (see Section 4-14).
No weld output; pilot light On.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-4).
Have Factory Authorized Service Agent check control board PC1.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-7).
Clean and tighten all weld connections.
When using multiple units, make sure all units connected with terminal strip TE1 are turned on.
Have Factory Authorized Service Agent check control board PC1.
No 115 volts AC output at duplex
receptacle and Remote 14 receptacle.
Reset supplementary protector CB1 (see Section 4-11).
No 230 volts AC output at duplex receptacle.
Reset supplementary protector CB3 (see Section 4-12).
No 24 volts AC output at Remote 14
receptacle.
Reset supplementary protector CB2 (see Section 7-3).
OM-246 011 Page 33
SECTION 8 − ELECTRICAL DIAGRAMS
Figure 8.1. Circuit Diagram For Sub Arc AC/DC 1000 (460 V Input) Model
OM-246 011 Page 34
244 959-C
OM-246 011 Page 35
Figure 8.2. Circuit Diagram For Sub Arc AC/DC 1250 (400 V Input) Model
OM-246 011 Page 36
247 290-D
OM-246 011 Page 37
SECTION 9 − PARTS LIST
5
6
7
2
9
8
3
10
1
4
12
11
15
16
14
13
. Hardware is common and
. 1000 Model Illustrated
not available unless listed.
247 435-D
Figure 9-1. Main Assembly
OM-246 011 Page 38
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly
. . 1 . . . . . . . . . . . 246960 . . Panel, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 2 . . . . . . . . . . +245938 . . Cover,Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . 217136 . . Label, Warning Electric Shock(Eng/Fr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . 176254 . . Label, General Precautionary Wordless Intl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . 184340 . . Channel, Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 5 . . . . . . . . . . . 026627 . . Gasket, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . 184344 . . Stop, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . 184342 . . Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . 184341 . . Bar, Cross Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . Fig.9-3 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . Z1 . . . 184350 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . 184359 . . Bracket, Mtg Terminal Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . T1 . . . 246546 . . Xfmr Assy, Power Main 460 V Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . T1 . . . 246550 . . Xfmr Assy, Power Main 400 V Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . 246874 . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . 184345 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . SR1 . . 246263 . . Rectifier, SCR Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . Fig. 9-2 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-246 011 Page 39
30
44
1
2
43
3
4
42
41
40
5
39
6
17
18
38
8
9
7
16
15
10
11
14
12
37
19
13
24
35
36
34
25
26
21
27
33
20
23
16
28
31
29
not available unless listed.
32
28
22
. Hardware is common and
. 1000 Model Illustrated
Figure 9-2. Front Panel Assembly
OM-246 011 Page 40
247 433-D
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Front Panel Assembly (Figure 9-1 Item 16)
. . . 1 . . . . . . . . . . . . . . 245321 . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 248445 . . Strip, Polycarbonate Clear .250 X 6.000 X 12.500 . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 248446 . . Latch, Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 248467 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . RC1 . . . . 604176 . . Rcpt, Str Dx Grd 2p3W 15A 125V *5−15r (460 V Models) . . . . . . . . . . . . .
. . . 6 . . . . RC1 . . . . 176355 . . Rcpt, Str 2p3W 16A 220V Flange Mtg (400 V Models) . . . . . . . . . . . . . . . .
. . . 7 . . . . . PL3 . . . . 249340 . . LED Assy, Blue w/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . S2 . . . . . 248658 . . Switch, Rocker SPST 15/10A 125/250VAC On−None−On Spd Term Blk
. . . 9 . . . . . S4 . . . . . 252263 . . Switch, Rocker 2PDT 15/10A 125/250VAC On−None−On . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . 171007 . . Knob, Pointer 1.670 Dia X .250 ID W/Set Screwplstc . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . 174991 . . Knob, Pointer 1.250 Dia X .250 ID W/Spring Clip−.21 . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Recessed (Order By Model And Serial Number) . . . . . . . . . .
. . . 13 . . . . . S5 . . . . . 246169 . . Switch, Rotary Multi−deck 12posn 1/4Amp PC Mtg . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . R5 . . . . . 030109 . . Pot, Cp Std Slot 1t 2. W 5k Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 248442 . . Panel, Recessed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . CB1-2 . . . 093995 . . Supplementary Pro,Man Reset 1p 15A 250VAC Frict (460 V Models) . . .
. . . 16 . . . CB1-3 . . . 093995 . . Supplementary Pro,Man Reset 1p 15A 250VAC Frict (400 V Models) . . .
. . . 17 . . . . . . . . . . . . . . 246369 . . Bracket, Mtg Receptacle (115V) (460 V Models) . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . 246370 . . Bracket, Mtg Receptacle (230V) (400 V Models) . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 170647 . . Bushing, Snap−In Nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . PC1 . . . . 244419 . . Circuit Card Assy, Control W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG11 . . . 163467 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . PLG12,13,15 152249 . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG14 . . . 115094 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 098691 . . Stand−off, No 6−32 X .500 Lg .250 Hex Stl M&F . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 244732 . . Baffle, Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . HD2 . . . . 244958 . . Transducer, Current 1000A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 245940 . . Bracket, Mtg LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . CR1 . . . . 000174 . . Relay, Encl 24VAC 3PDT 10A/120VAC 11Pin Flange Mtg . . . . . . . . . . . . .
. . . 25 . . . . R3,4 . . . . 136076 . . Resistor, WW FXD 30W 200 Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . C19, 20 . . . 249477 . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . RC7 . . . . 134735 . . Conn, Circ MS/CPC 14Skt Size 20 Rcpt Panel Pushin . . . . . . . . . . . . . . . .
. . . 28 . . . C9, 10 . . . 246168 . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 190960 . . Terminal Assy, Power Output (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 601840 . . . . Nut, 500−13 .88hex .32h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 191137 . . . . Bus Bar, Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 191138 . . . . Terminal Board, Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 601839 . . . . Nut, 500−13 .75hex .44h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 038900 . . . . Stud, Brs .500−13 X 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 602247 . . . . Washer, Flat .531ID x 1.062OD x .095t Stl Pld ANSI.500 . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 605787 . . . . Washer,Tooth.512 ID x 0.900 OD x .045 T Stl Pld Int.500 A . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 010546 . . Bushing, Snap−In Nyl .375 ID X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . S3 . . . . . 011609 . . Switch, Tgl Spdt 15A 125VAC On−none−on Spd Term Chr . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 246099 . . Bracket, Mtg Term Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 005107 . . Bolt, Crg Stl .250−20 X .750 Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . TE2 . . . . 246951 . . Block, Term 20 Amp 3 Pole Quick Conn 20−12AWG Wire Labeled . . . .
. . . 35 . . . . TE1 . . . . 246950 . . Block, Term 20 Amp 3 Pole Quick Conn 20−12AWG Wire Labeled . . . .
. . . 36 . . . . . . . . . . . . . . 246170 . . Nameplate, SUBARC AC/DC 1000/1250 Lower . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 161303 . . Spring, CPRSN .600 OD X .072 Wire X 1.500 Pld . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . +172587 . . Cover, Output Stud Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . . 160935 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . 217861 . . Label, Warning Electric Shock Can Kill Etc (FR) (460 V Model) . . . . . . . .
. . . 40 . . . . . . . . . . . . . . 194557 . . Label, Warning Electric Shock Can Kill Etc Wordless (400 V Models) . .
. . . 41 . . . . . S1 . . . . . 248654 . . Switch, Rocker SPST 15/10A 125/250VAC 28V Wht Lamp
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Off−None−On Spd Term Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
3
1
1
3
1
4
1
1
1
1
2
2
1
2
2
4
1
1
2
2
2
2
2
1
1
8
1
1
1
3
1
3
1
1
1
OM-246 011 Page 41
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Front Panel Assembly (Figure 9-1 Item 16) (continued)
. . . 42 . . . . . PL2 . . . . 247090 . . LED Assy, Yellow W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 168343 . . Hinge, Cont Polypropylene Copolymer 2.000 L W/.125 . . . . . . . . . . . . . . . 2
. . . 44 . . . . . . . . . . . . . . 248450 . . Latch, Lock w/Key (Wing Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
4
not available unless listed.
6
5
3
7
2
8
1
9
13
14
4
20
15
16
21
10
11
12
19
18
17
Figure 9-3. Rear Panel Assembly
OM-246 011 Page 42
247 434-C
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-3. Rear Panel Assembly (Figure 9-1 Item 9)
. . . 1 . . . . . FM . . . . . 032605
. . . 2 . . . . CR2 . . . . 006393
. . . 3 . . . . . . . . . . . . . . 222352
. . . 4 . . . . R1,2 . . . . 097459
. . . 5 . . . . . . . . . . . . . . 222347
. . . 6 . . . . . . . . . . . . . +245936
. . . 7 . . . . . . . . . . . . . . 218280
. . . 8 . . . . . . . . . . . . . . 245937
. . . 9 . . . . . . . . . . . . . . 217860
. . . 9 . . . . . . . . . . . . . . 194466
. . . 10 . . . . . W . . . . . 252348
. . . . . . . . . . . W1 . . . . . 213446
. . . 11 . . . . . . . . . . . . . . 252264
. . . 12 . . . . . . . . . . . . . . 252349
. . . 13 . . . . . . . . . . . . . . 252265
. . . 14 . . . . . . . . . . . . . . 159034
. . . 15 . . . . . . . . . . . . . . 156065
. . . 16 . . . . . . . . . . . . . . 030170
. . . 17 . . . . . . . . . . . . . . 246208
. . . 18 . . . . . T2 . . . . . 246003
. . . 18 . . . . . T2 . . . . . 246602
. . . 19 . . . . . . . . . . . . . . 188403
. . . 20 . . . . HD1 . . . . 148417
. . . 21 . . . . . . . . . . . . . . 134201
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Motor, Cap Perm SP 1/4HP 230VAC 1625RPM . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 24VAC DPDT 10A/120VAC 8Pin Flange Mtg . . . . . . . . . . . . .
Windtunnel, 20 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor, WW FXD 375 W 20 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade, Fan 20.000 3WG 13DEG .500 Bore CW AL . . . . . . . . . . . . . . . . . .
Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hinge, Cont Polyolefin Copolymer 2.000 L W/.125H . . . . . . . . . . . . . . . . . .
Door, Primary Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock And Input Pwr (FR) . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock And Input Power (CE) . . . . . . . . . . . . . . . .
Contactor, Size S3 3P AC 140 Amp 24V 50/60 Hz . . . . . . . . . . . . . . . . .
Interlock, Cntor No Size 3−1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rail, Din . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block, Power Splice 3P 175 Amp 600V AC/DC . . . . . . . . . . . . . . . . . . . . . .
Holder, Fuse Mintr 10.3mm X 33.3 To 38.1mm Panel Mt . . . . . . . . . . . . . .
Fuse, Crtg .5 Amp 600V Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Snap-in Nyl .750 ID X 1.000 Mtg Hole . . . . . . . . . . . . .
Bracket, Mtg Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Xfmr, Control 100VA 24V 460V Pri 60Hz (460 V Models) . . . . . . . . . . . . .
Xfmr, Control 100VA 24V 400V Pri 50Hz (400 V Models) . . . . . . . . . . . . .
Bracket, Mtg LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer, Current 1000A Module Supply V +/− 24V . . . . . . . . . . . . . . . .
Stand−Off Support, PC Card .312/.375W/Post & Lock .43 . . . . . . . . . . . .
1
1
1
2
1
1
3
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
4
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-246 011 Page 43
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2011
(Equipment with a serial number preface of MB 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 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
* Spoolmate Spoolguns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.
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
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to an
International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Engine Driven Welding 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
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
Miller’s True Blue Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4) payment
of or credit for the purchase price (less reasonable depreciation
based upon actual use) upon return of the goods at customer’s risk
and expense. Miller’s option of repair or replacement will be F.O.B.,
Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized
service facility as determined by Miller. Therefore no
compensation or reimbursement for transportation costs of any
kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2011−01
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
 2011 Miller Electric Mfg. Co.
2011−01
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