Miller | MK340062G | Owner Manual | Miller SUBARC DC 650/800, 1000/1250 DIGITAL POWER SOURCES User manual

Miller SUBARC DC 650/800, 1000/1250 DIGITAL POWER SOURCES User manual
OM-265363P
2019-07
Processes
Submerged Arc (SAW) Welding
Electroslag (ESW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Arc Welding Power Source
SubArc DC 650, 1000
SubArc DC 800 CE, 1250 CE
Digital Power Sources
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Submerged (SAW)
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, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank1 2019−01
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. SubArc System Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Typical Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Terminal Strip TE2 and Remote Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Terminal Strip TE1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAKING WELD OUTPUT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Basic Subarc (SAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Typical Connection For CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Connecting Multiple Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − POWER SOURCE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PLC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Automation Interface Hardware Configuration (PLC Users Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Connection To PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Example Power Source Operation Using A PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 10 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. SubArc System Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Power Source Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Troubleshooting Table For Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
COMPLETE PARTS LIST − Available at www.MillerWelds.com
37
37
39
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DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
Product
SUBARC DC 1250 DIGITAL 50HZ CE
SUBARC DC 1000 DIGITAL
SUBARC DC 800 DIGITAL 50HZ CE
SUBARC DC 650 DIGITAL
907625
907624
907623
907622
Council Directives:
• 2014/35/EU Low voltage
• 2014/30/EU Electromagnetic compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
March 27, 2017
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
266179C
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
Stock Number
SUBARC DC 1250 DIGITAL
SUBARC DC 1000 DIGITAL
SUBARC DC 800 DIGITAL
SUBARC DC 650 DIGITAL
907625
907624
907623
907622
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.19
Health Ef­
fects
10 cm
0.04
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.07
3 cm
0.04
3 cm
0.08
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
10 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
72 cm
Tested by:
275579-A
Tony Samimi
Date tested:
2016-03-01
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2018−01
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-265363 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-265363 Page 2
D Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use correct procedures and equipment of adequate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
OM-265363 Page 3
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment
perform this installation.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is electromagnetically
compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-265363 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som_2018−01_fre
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Éteignez l’unité, débranchez le courant électrique, et déchargez
les condensateurs d’alimentation selon les instructions indiquées
dans le manuel avant de toucher les pièces.
OM-265363 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
OM-265363 Page 6
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas couper ou souder des jantes ou des roues. Les pneus
peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-265363 Page 7
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 5060 Spec-
trum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N,
Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA
Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-265363 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
. A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2017−04
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017−04
Disconnect input plug or power before working on machine.
Safe5 2017−04
Keep your head out of the fumes.
Safe6 2017−04
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2017−04
OM-265363 Page 9
. A complete Parts List is available at www.MillerWelds.com
Do not remove or paint over (cover) the label.
Safe20 2017−04
Disconnect input plug or power before working on machine.
Safe30 2012−05
?
?
V
A
Consult rating label for input power requirements.
Safe34 2012−05
Read Owner’s Manual and inside labels for connection points and procedures.
ÍÍ
ÍÍ
Safe67 2012−06
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.
Safe37 2017−04
Environmental Protection Use Period (China)
Safe123 2016−06
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
?V
ÍÍ
ÍÍ
3
Move jumper links as shown on inside label to match input voltage at
job site. Include extra length in grounding conductor and connect
grounding conductor first. Connect line input conductors as shown on
inside label. Double-check all connections, jumper link positions, and
input voltage before applying power.
Safe68 2012−06
Close door before turning on unit.
Safe69 2012−06
OM-265363 Page 10
. A complete Parts List is available at www.MillerWelds.com
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
V
Hz
Amperage
Voltage
Hertz
Output
X
IP
S
Duty Cycle
Shielded Metal
Arc Welding
(SMAW)
Degree Of
Protection
Gas Tungsten Arc
Welding (GTAW)
Suitable For
Welding In An
Environment With
Increased Risk Of
Electric Shock
Submerged Arc
Welding (SAW)
Arc Force (DIG)
Line Connection
Input
Circuit Breaker
Supplementary
Protector
Amperage/Voltage
Control−Panel
Three-Phase
Transformer
Rectifier
Start
Percent
Stop
Direct Current
(DC)
Remote
U0
U1
U2
S1
Single Phase
Wire Feed Inch
Up
Three Phase
Rated No−Load
Voltage (OCV)
Primary Voltage
Conventional
Load Voltage
Product of Voltage
and Current (KVA)
On
Protective Earth
(Ground)
Wire Feed Inch
Down
Crater Time
Negative Weld
Output Terminal
Positive High
Inductance Weld
Output Terminal
Positive Low
Inductance Weld
Output Terminal
Program
Flux
Postflow Timer
Temperature
Off
I1
I2
Primary Current
Preflux Timer
Gas Metal Arc
Welding (GMAW)
Start Time
Rated Welding
Current
OM-265363 Page 11
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for the power sources is located on the front or the rear of the machine. Use the rating labels to determine
input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Software Licensing Agreement
The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at
https://www.millerwelds.com/eula and are incorporated by reference herein.
4-3. Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-4, 5-5 and 5-6 for information on
connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Rated
Welding
Output**
Model
650 A @ 44
Volts DC,
100% Duty
Cycle
DC 650
Digital
Amperage/Voltage
Range DC
Amperes Input at
Rated Load Output,
60 Hz, Three-Phase
Amperes Input at
Rated Load Output,
50 Hz, Three-Phase
230 V 460 V 575 V 380 V 400 V 440 V
50 − 815 A In CC
Mode
20 − 44 V In Subarc
Mode
DC 800
Digital
815 A @ 44
Volts DC,
60% Duty
Cycle
DC
1000
Digital
1000 A @ 44
Volts DC,
100% Duty
Cycle
100 − 1250 A In CC
Mode
DC
1250
Digital
1250 A @ 44
Volts DC,
60% Duty
Cycle
20 − 44 V In Subarc
Mode
4-4.
Max
OCV−DC
126
3.8*
63
1.9*
50.4
1.4*
75 Vpk
95
1.9*
180
5.8*
90
2.9*
90
1.8*
KVA
KW
50
1.52*
34.8
0.76*
73
3.2*
53
0.5*
83
1.6*
72
2.4*
68 Vpk
135
5.2*
128
5.0*
117
4.5*
SubArc System Compatibility
The following accessory models will function with the SubArc DC 650/800 and 1000/1250 Digital power sources. The interface will automatically detect
the power source and wire drive type connected.
Interfaces:
300936 − SubArc Interface Digital
300937 − SubArc Interface Analog
Wire Drives:
300938 − SubArc Wire Drive 400 Digital Low Voltage
300938001 − SubArc Wire Drive 400 Digital Low Voltage For Tractors
300939 − SubArc Strip Drive 100 Digital Low Voltage
300940 − SubArc Strip Drive 100 Digital Low Voltage w/Mounting Bracket
300941 − SubArc Wire Drive 780 Digital Low Voltage
Flux Hopper:
300942 − SubArc Flux Hopper Digital Low Voltage
4-5. Static Characteristics
The static (output) characteristics of the welding power source can be described as drooping during the SAW process. Static characteristics
are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact the factory for
specific information on the static characteristics of the welding power source.
OM-265363 Page 12
. A complete Parts List is available at www.MillerWelds.com
4-6. Environmental Specifications
A. IP Rating For All Equipment Covered In This Manual
IP Rating
IP23
This equipment is designed for outdoor use.
IP23 2017−02
B. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
14 to 104°F (−10 to 40°C)
−4 to 131°F (−20 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Temp_2016- 07
C. Information On Electromagnetic Compatibility (EMC) For DC 1000/1250 Amp Power Source Models
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
IEC/TS 61000−3−4 can be used to guide parties concerned by the installation of arc welding equipment with an input current greater than 75
A in a low-voltage network.
ce-emc 5 2014-07
D. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
OM-265363 Page 13
. A complete Parts List is available at www.MillerWelds.com
4-7. Duty Cycle And Overheating
A. Duty Cycle And Overheating For DC 650/800 Amp Models
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle
Continuous Welding
Overheating
0
A/V
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 / Ref. 168918
B. Duty Cycle And Overheating For DC 1000/1250 Amp Models
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle
Continuous Welding
Overheating
A/V
0
15
Minutes
OM-265363 Page 14
OR
Reduce Duty Cycle
duty1 4/95 / SA-191157-B
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Dimensions And Weights
Dimensions
A
C
B
F
G
A
30 in. (762 mm)
Including lift eye
B
23 in. (584 mm)
C
38 in. (965 mm)
Including strain relief
D
33-3/4 in. (857 mm)
E
1-1/4 in. (32 mm)
F
20 in. (508 mm)
G
1-1/8 in. (29 mm)
H
7/16 in. (11 mm) Dia.
H
4 Holes
D
Weight
650/800 Amp Models: 545 lb (247 kg)
1000 Amp Models: 644 lb (292 Kg)
E
Front
1250 Amp Models: 650 lb (295 Kg)
800453-B / 801530
Notes
OM-265363 Page 15
. A complete Parts List is available at www.MillerWelds.com
5-2. Selecting A Location
Movement
!
Do not move or operate unit
where it could tip.
1
OR
2
Location And Airflow
3
18 in.
(460 mm)
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
loc_large 2018-08
5-3. Typical Equipment Location
1
2
3
4
5
6
Welding Power Source
Side Beam
Interface
Spool Support
Wire Drive Assembly
Torch
4
3
5
2
1
6
Ref. 131138-A
OM-265363 Page 16
. A complete Parts List is available at www.MillerWelds.com
5-4. Electrical Service Guide
Elec Serv 2011−08
A. Electrical Service Guide For DC 650/800 Digital Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
60 Hz Models (DC 650 Digital)
50 Hz Models (DC 800 Digital)
Input Voltage (V)
230
460
575
380
400
440
Input Amperes (A) At Rated Output
126
63
50.4
95
90
83
Time-Delay Fuses 2
150
70
60
90
90
80
Normal Operating Fuses 3
200
90
80
125
110
100
1 (50)
6 (16)
6 (16)
4 (25)
4 (25)
4 (25)
208
(64)
328
(100)
513 (156)
335
(102)
371
(113)
449 (137)
6 (16)
8 (10)
8 (10)
6 (16)
6 (16)
8 (10)
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG
4
(mm 2)
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4 (mm 2)
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
B. Electrical Service Guide For DC 1000/1250 Digital Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
60 Hz Models (DC 1000 Digital)
50 Hz Models (DC 1250 Digital)
Input Voltage (V)
230
460
575
380
400
440
Input Amperes (A) At Rated Output
180
90
72
135
128
117
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
225
110
90
125
125
110
Normal Operating Fuses 3
250
125
110
175
150
150
3/0 (95)
3 (35)
4 (25)
2 (35)
2 (35)
3 (35)
204
(62)
337
(103)
438 (134)
322
(98)
357
(109)
358 (109)
4 (25)
6 (16)
6 (16)
6 (16)
6 (16)
6 (16)
Min Input Conductor Size In AWG 4 (mm 2)
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4 (mm 2)
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-265363 Page 17
. A complete Parts List is available at www.MillerWelds.com
5-5. Placing Jumper Links
!
Disconnect and lockout/tagout
input power before installing or
moving jumper links. Follow
established procedures regarding the installation and removal
of
lockout/tagout
devices.
Check input voltage available at site.
1
DC 650/800 Digital Models
2
3
Jumper Link Label For DC 800
Digital and DC 1250 Digital
Machines
Jumper Link Label For DC 650
Digital and DC 1000 Digital
Machines
Jumper Links
Move jumper links to match input voltage.
Close and secure access door, or go
on to Section 5-6.
1
193546-A
2
3
193526-A
Do not overtighten
jumper link nuts.
Tools Needed:
3/8 in.
3/8 in.
Ref. 265207-A
OM-265363 Page 18
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-265363 Page 19
. A complete Parts List is available at www.MillerWelds.com
5-6. Connecting 3-Phase Input Power
3
= GND/PE Earth Ground
8
7
10
9
2
4
6
1
5
3
L1
6
L2
L3
=
4
GND/PE Earth Ground
3
5/32 in.
Tools Needed:
3/8, 1/2 in.
3/8 in.
Ref. input3 2015−01 − Ref. 803766-C / 800103-D / Ref. 801116-A
OM-265363 Page 20
. A complete Parts List is available at www.MillerWelds.com
5-6. Connecting 3-Phase Input Power (Continued)
!
Installation must meet all National
and Local Codes − have only qualified
persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow conductor to supply grounding
terminal first, and never to a line terminal.
See rating label on unit and check input voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 5-4. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Close and secure access door on welding
power source.
Welding Power Source Input Power Connections
Disconnect
Device
Connections
2
Strain Relief (Customer Supplied)
Input
Power
7
Install strain relief of proper size for unit and
conductors. Route conductors (cord)
through strain relief and tighten screws.
Disconnect Device (switch shown in
OFF position)
8
Disconnect Device (Supply) Grounding
Terminal
3
9
Disconnect Device Line Terminals
4
Welding Power Source Grounding
Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source grounding terminal first. Connect remaining end to
grounding terminal in disconnect device.
5
6
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.
10 Over-Current Protection
Welding Power Source Line Terminals
Input Conductors L1 (U), L2 (V) And L3
(W)
Select type and size of over-current protection using Section 5-4 (fused disconnect
switch shown).
Connect input conductors L1 (U), L2 (V) and
L3 (W) to welding power source line
terminals.
Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.
Ref. input3 2015−01
Notes
OM-265363 Page 21
. A complete Parts List is available at www.MillerWelds.com
SECTION 6 − SYSTEM CONNECTIONS
6-1.
Terminal Strip TE2 and Remote Receptacle RC1 Information
Function
Electrical Input Power
Socket On RC1
Terminal On TE2
Contact Information
A, B
−
24 VAC. Protected by circuit breaker CB2.
C, D
−
24 VAC common.
J
−
+Accessory RS−485 communication.
V
−
−Accessory RS−485 communication.
Q
−
Accessory serial communication common.
H
−
Contact E/F shield drain lead.
P
−
+Power source RS−485 communication.
Power Source Serial
Communication
N
−
−Power source RS−485 communication.
Z
−
Power source serial communication common.
Shield
G
−
Contact H/J shield drain lead.
Accessory Serial Communication
Shield
PS/PS Communication
K
−
Communication link in.
Power Source Synchronization
E
−
Synchronization in.
Volt Sense
W
−
+ Volt sense.
X
−
Reserved for − volt sense.
N
−
Contact M/L shield drain lead.
−
N
Voltage sensing signal from Work weld output terminal.
−
P
Voltage sensing signal from Electrode weld output terminal.
−
TP
Shield
Remote Voltage Sensing
Test point.
− Not Applicable
!
Turn Off welding power
source before opening
access door.
1
2
Access Door
Remote Receptacle RC1
(Mounted Inside Access Area)
Terminal Strip TE2
SubArc Interface
3
4
4
Connect RC1 on SubArc Interface
to Remote receptacle RC1 on power source.
5
Modbus RTU
For use with optional PLC control.
5
1
. A DC 650/800 model is
shown.
Location is the same for DC
1000/1250 models.
2
3
Ref. 265207-A / 265690-B
OM-265363 Page 22
. A complete Parts List is available at www.MillerWelds.com
6-2. Terminal Strip TE1
!
Turn Off welding power
source before opening
access door.
1
Access Hole
Remove knockout or cover from
access hole and install customer
supplied strain relief. Route cable
connections through the access
hole.
2
3
12-Pole Terminal Strip
Label
Remove and retain screws and
open terminal strip panel. Make
connections per the label on the
panel. Close panel and replace
screws.
. A DC 650/800 model is shown.
Location is the same for DC
1000/1250 models.
2
1
3
A
B
10VDC
REMOTE
CONTACTOR
C
E
RMT CMD OUTPUT
REF
CMD
+10VDC 0–+10VDC
D
F
H
M
RMT
CURRENT VOLTAGE
COMM FEEDBACK FEEDBACK
(1V/100A)
(1V/10V)
L
RMT
POWER
ON/OFF
261064-A
Tools Needed:
265207-A / 261064-A
Terminal
Function Information
A
10 VDC remote contactor.
B
Connecting terminals A and B will enable output.
C
Remote command reference +10 VDC. Connecting terminals C, D, and E will allow remote control.
E
Output command 0 − +10 VDC. Connecting terminals C, D, and E will allow remote control.
D
Remote common.
F
Connecting terminals F and D will provide current feedback (1V/100A).
H
Connecting terminals H and D will provide voltage feedback (1V/10A).
M
Remote power on/off.
Connecting a switch to terminals M and L allow the power source to be remotely turned on or off.
L
OM-265363 Page 23
. A complete Parts List is available at www.MillerWelds.com
SECTION 7 − MAKING WELD OUTPUT CONNECTIONS
7-1. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x3/0 (3x95)
600
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
700
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
800
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
4x4/0 (4x120)
900
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
1000
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
1250
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
4x3/0 (4x95)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use.
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08
7-2. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
. For welding output terminal connections see Sections 7-4 and 7-5.
1
2
265207-A
output term1 2015−02
OM-265363 Page 24
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7-3. Connecting Weld Output Cables
2
3
6
1
4
Tools Needed:
5
3/4 in. (19 mm)
803778-B
!
!
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.
. Do not place anything between weld
1
2
3
4
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
5
Weld Cable Terminal
6
Copper Bar
Correct Weld Cable Connection
Incorrect weld Cable Connection
Weld Output Terminal
Supplied Weld Output Terminal Nut
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.
connecting weld output cables 3−2010
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-265363 Page 25
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7-4. Basic Subarc (SAW) Welding
. Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive extension cable, drive rolls, torch,
welding wire, weld cables, remote voltage sense leads, flux hopper, flux hopper extension cable, and flux system for the desired application.
A. Basic Subarc (SAW) Equipment Connections For DCEP
!
Turn off welding power
source and weld control before making connections.
. Use
remote voltage sense
leads in all applications.
. Suggested size for remote volt-
age sense wire is 12 gauge or
larger.
. A DC 650/800 Digital model is
shown. Connections are the
same for DC 1000/1250 Digital
models.
Flux System
SubArc Interface
Flux Hopper
Motor Extension Cable
Wire
Drive
Assembly
Electrode Volt-Sense Lead
From Motor Cable
From Terminal Strip
TE2 Terminal N
Workpiece
Weld Cables
Ref. 254240-A
OM-265363 Page 26
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B. Remote Voltage Sensing Leads Placement Guidelines For A Single Arc (Required)
Electrode
Remote Voltage
Sense Lead
BAD
Work
Remote Voltage
Sense Lead
Wire
Drive
Sense lead is affected by weld
current.
Welding Power
Source
Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.
Work
Clamp
Work
Remote Voltage
Sense Lead
BEST
Sense leads are out of the current
paths.
Sense leads detect arc voltage accurately.
Best starts, arcs and most reliable
results.
Electrode
Remote Voltage
Sense Lead
Welding Power
Source
Wire
Drive
Work
Clamp
Ref. 804108-A
OM-265363 Page 27
. A complete Parts List is available at www.MillerWelds.com
C. Sensing Leads Placement Guidelines For Multiple Arcs
Lead
Wire
Drive
BAD
Wire
Drive
Current flow from lead affects trail
sense.
Welding Power
Source
Electrode Remote
Volt
Sense Leads
Work
Remote Voltage
Sense Leads
Lead
Current flow from trail affects lead
sense.
Trail
Trail
Neither sense lead picks up the
correct work voltage, causing
starting and welding arc instability.
Welding Power
Source
Work
Clamp
Trail
Lead
Wire
Drive
Wire
Drive
Lead
Electrode Remote
Volt
Sense Leads
Welding Power
Source
BAD
Trail sense lead is affected by
weld current from trail.
Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.
Work
Remote Voltage
Sense Leads
Lead
Lead sense is affected by weld
current from lead.
Trail
Work
Clamp
Work
Clamp
Trail
Welding Power
Source
Lead
Trail
Lead
BEST
Wire Drive
Electrode Remote
Volt Sense
Leads
Both sense leads are out of the
current paths.
Both sense leads detect arc voltage accurately.
No voltage drop between lead and
trail sense.
Wire Drive
Welding Power
Source
Work Remote Voltage
Sense Leads
Trail
Lead
Trail
Best starts, arcs and most reliable
results.
Welding Power
Source
Work
Clamp
Trail
Lead
Ref. 804108-A
OM-265363 Page 28
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D. Basic SubArc (SAW) Equipment Connections For DCEN
!
Turn off welding power
source and weld control
before making connections.
. Use
remote voltage sense
leads in all applications.
. Suggested size for remote volt-
age sense wire is 12 gauge or
larger.
. Tie-off
and secure electrode-volt sense lead from motor cable when setting up to operate in DCEN.
. A DC 650/800 Digital model is
shown. Connections are the
same for DC 1000/1250 Digital
models.
Flux System
SubArc Interface
Flux Hopper
Electrode Volt-sense Lead
From Motor Cable
Motor Extension Cable
Wire
Drive
Assembly
From Terminal Strip
TE2 Terminal N
From Terminal Strip
TE2 Terminal P
Workpiece
Weld Cable
Ref. 254240-A
OM-265363 Page 29
. A complete Parts List is available at www.MillerWelds.com
7-5. Typical Connection For CAC-A Process
1
3
2
4
5
272583-B
!
1
Turn off welding power source before making connections.
2
For CAC-A process connect carbon arc
cutting torch to positive (+) weld terminal.
Connect work lead to negative (−) output
terminal.
DC Power Source
3
5
OM-265363 Page 30
Electrode Holder (Carbon Arc)
Compressed Air Line
4
Work Lead
Workpiece
. A complete Parts List is available at www.MillerWelds.com
7-6.
Connecting Multiple Units
!
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.
Parallel Connections For Digital 650/800 Machines:
CONTROLLING UNIT
Turn Off welding power
source
before
making
connections.
To use two or more units with one
electrode, make connections as
shown.
FOLLOWING UNIT(S)
RC1
RC1
RC2
(WHITE)
. The first unit controls voltage.
RC2
(WHITE)
All remaining units supply additional current.
. Only like power sources can be
paralleled.
TO WORK
TO WORK
To RC1 ON NEXT
DC 650 Digital UNIT
(OR DC 800 Digital UNIT
IF PARALLELING 800”S)
WHITE
TO ELECTRODE
Parallel Connections For Digital 1000/1250 Machines:
254241-A
CONTROLLING UNIT
RC1
RC1
RC2
(WHITE)
TO WORK
WHITE
TO ELECTRODE
FOLLOWING UNIT(S)
RC2
(WHITE)
TO WORK
To RC1 ON NEXT
DC 1000 Digital UNIT
(OR DC 1250 Digital UNIT
IF PARALLELING 1250”S)
265208-A
OM-265363 Page 31
. A complete Parts List is available at www.MillerWelds.com
SECTION 8 − POWER SOURCE OPERATION
8-1. Controls
1
4
5
6
PROCESS
OUTPUT
3
A/V ADJUST
1 Process Selector Switch
Place switch in position for desired process.
• Subarc Mode − For SAW (Subarc)
applications.
• CC Mode - For gouging applications.
2 Output Control Switch (Contactor)
For weld output, place switch in On position.
Switch is disabled when a SubArc Interface
is connected to Remote Receptacle RC1
and powered on, or when a PLC has active
control through the Modbus RTU connector.
It is disabled if the power source is a
following unit in parallel configuration.
3 Output On LED
OM-265363 Page 32
262962-B
2
!
!
Output is on and weld output studs
are energized when LED is lit.
Turn Off power before connecting
remote device.
For front panel control of output, place switch
in On position. For remote control of output,
place switch in Remote position, and
connect remote device to RC1. Remote
control provides full range of unit output
regardless of A/V Adjust control setting. If
the output is on before a remote accessory
is powered on, the power source will ignore
the accessory until the output is turned off.
4 Amperage/Voltage Adjustment Control
When Process Selector switch is in the
Constant Current position, turn control
clockwise to increase amperage. Read
amperage from outer scale of control.
Numbers on scale are for reference only.
When the Process Selector switch is in the
Subarc position, Control can be adjusted
while welding.
5 Status/Trouble Light
When a fault occurs, LED flashes a
sequence code to identify the fault (see
section 10-1).
6 Power Switch With Indicator Light
. A complete Parts List is available at www.MillerWelds.com
SECTION 9 − PLC OPERATION
9-1.
Automation Interface Hardware Configuration (PLC Users Only)
!
Disconnect and lockout/tagout input power before connecting input conductors from
unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
1
Switch DIP 1
1
Configure switch DIP 1 on Automation Interface board PC4 to match the
network baud rate and parity settings, and set the MODBUS address
for this device. (see Table 9-1 thru
Table 9-3).
Table 9-2. Baud Rate Data
Table 9-1. MODBUS Address
DIP1
DIP1
Address
1
2
3
4
ON
ON
ON
ON
40
OFF
ON
ON
ON
41
ON
OFF
ON
ON
42
OFF
OFF
ON
ON
43
ON
ON
OFF
ON
44
OFF
ON
OFF
ON
45
ON
OFF
OFF
ON
46
OFF
OFF
OFF
ON
47
Default Setting
Rate
5
6
ON
ON
9600
OFF
ON
19200
ON
OFF
38400
OFF
OFF
reserved
Table 9-3. Parity Data
DIP1
ON
ON
ON
OFF
60
OFF
ON
ON
OFF
61
7
8
Parity
ON
OFF
ON
OFF
62
ON
ON
EVEN
OFF
OFF
ON
OFF
63
OFF
ON
ODD
ON
ON
OFF
OFF
64
ON
OFF
NONE
OFF
ON
OFF
OFF
65
OFF
OFF
reserved
ON
OFF
OFF
OFF
66
OFF
OFF
OFF
OFF
67
Default Setting
Default Setting
265207-B
OM-265363 Page 33
. A complete Parts List is available at www.MillerWelds.com
9-2.
Connection To PLC
The automation interface uses an RJ45 connector to communicate MODBUS RTU over RS485.
. The automation interface is NOT an Ethernet connection!
The pin connections are as follows:
Table 9-4. Connector Pinout
Function
RJ45 Pin
Circuit
4
D+
5
D−
8
Common
Case
Shield
Digital Communication
Shield
9-3.
1
2
3
4
5
6
7
8
9
Example Power Source Operation Using A PLC
To enable welding control from the Automation Interface, set the “Automation Enable” bit (0x4000) in the Command Flags register
(MODBUS Holding Register 101).
Set desired Weld Mode by writing MODBUS Holding Register 105 using look-up table Table 9-6.
Obtain Minimum and Maximum values by reading from Input Registers section 300 (See Table 9-8).
Set all relevant parameters (MODBUS Holding Registers 102-107) to their desired values. They must be within the minimum and maximum
values read in Step 2. Verify the values are correct by reading Input Registers 102-107.
Enable weld output by setting the Output Enable Flag to 1 in the Command Flags register (MODBUS Holding Register 101).
Voltage & Current Feedback values can be read from Input Registers section 200 (See Table 9-8).
Disable weld output by clearing the Output Enable Flag to 0 in the Command Flags register (MODBUS Holding Register 101).
If there is no communication from the MODBUS master for a period greater than one second, the power source will reset all registers to
their default value. Communication can consist of reading or writing.
It is recommended to continuously poll all welding parameters via the MODBUS master.
Table 9-5. MODBUS Function Codes
Function
Function Code
Read Input Register
4
Read Holding Register
3
Write Single Register
6
Write Multiple Register
16
Read/Write Multiple Register
23
Table 9-6. MODBUS Holding Registers
Register Address
Register Name
Register Description
PDU
MODBUS
100
101
Command Flags
101
102
Weld Voltage Command
Voltage command in 0.1V (used for CV & CV+C)
102
103
Weld Current Command
Current command in 1A (used for CC & CV+C)
103
104
Weld Wire Speed
104
105
Weld Mode
105
106
Run-In Speed Percentage
106
107
Burn Back Time
107
108
Drive Roll Diameter
OM-265363 Page 34
See Table 9-7.
Wire speed in IPM (only an initial guess in CV+C)
See Table 9-10.
Run-in wire speed percentage (%) of weld wire set-point
Time in which power source is on, with wire stopped, in milliseconds.
Diameter in 0.001 in. Only used when RAD 100 is connected
. A complete Parts List is available at www.MillerWelds.com
Table 9-7. Command Flags (MODBUS 101)
Flag Name
Bitmask
Description
Output Enable
0x0001
Enable Weld Output
Wire Jog Up
0x0002
Feed Wire Up
Wire Jog Down
0x0004
Feed Wire Down
Flux On
0x0008
Open Flux Valve
Motor CW
0x2000
Motor Direction (Clockwise=1)
Automation Enable
0x4000
Enable Control From PLC
Reset Faults
0xC000
Fault Reset (All Other Bits MUST Be 0)
Reserved
0x0010 - 0x1000
Reserved For Future Use (MUST Be 0)
Table 9-8. Input Registers
Register Address
PDU
MODBUS
Register Name
Register Description
100
101
Command Flags
101
102
Weld Voltage Command
102
103
Weld Current Command
103
104
Weld Wire Speed
104
105
Weld Mode
105
106
Run-In Speed Percentage
106
107
Burn Back Time
107
108
Drive Roll Diameter
200
201
Status Flags
201
202
Voltage Feedback
Voltage feedback (volts x 10)
202
203
Current Feedback
Current feedback (amps)
203
204
Help Code
204
205
Wire Feed Speed Feedback
205
206
Program Number
Used for holding register verification (see Table 9-6).
System Feedback Values
See Table 9-9.
System help code during errors (0 otherwise)
WFS feedback (IPM)
Present active program number
Minimum/Maximum Values (Dependent Upon Power Source, Motor And Weld Mode)
300
301
Min Voltage
Minimum voltage (0.1V) for MODBUS 102
301
302
Max Voltage
Maximum voltage (0.1V) for MODBUS 102
302
303
Min Current
Minimum current (1A) for MODBUS 103
303
304
Max Current
Maximum current (1A) for MODBUS 103
304
305
Min WFS
Minimum wire feed speed (IPM) for MODBUS 104
305
306
Max WFS
Maximum wire feed speed (IPM) for MODBUS 104
306
307
Min Burnback Time
Minimum burnback time (ms) for MODBUS 107
307
308
Max Burnback Time
Maximum burnback time (ms) for MODBUS 107
308
309
Min Drive Roll Diameter
Minimum roll diameter (0.001 in.) for MODBUS 108
309
310
Max Drive Roll Diameter
Maximum roll diameter (0.001 in.) for MODBUS 108
400
401
Power Source Version
High byte – major version # / low byte – minor version #
401
402
Automation Board Version
High byte – major version # / low byte – minor version #
402
403
Motor Board Version
High byte – major version # / low byte – minor version #
403
404
Display Board Version
High byte – major version # / low byte – minor version #
System Information
OM-265363 Page 35
. A complete Parts List is available at www.MillerWelds.com
Table 9-9. Status Flags (MODBUS 201)
Flag Name
Bitmask
Description
Valid Arc
0x0001
A valid arc has been detected.
Output On
0x0002
The power source output is on.
Run In
0x0004
The power source is in Run In.
Weld
0x0008
The power source is in the weld state.
Burnback
0x0010
The power source is in the burnback State.
Error
0x8000
The power source is in an Error Condition (read MODBUS Input Register 204).
Table 9-10. Weld Mode Look Up Table
Line Input Frequency (Hz)
Mode
Balance
60 Hz Line
50 Hz Line
Weld Mode Code
CV
Electrode Positive
−−
−−
0x0000
CV+C
Electrode Positive
−−
−−
0x4000
CC
Electrode Positive
−−
−−
0x8000
Notes
OM-265363 Page 36
. A complete Parts List is available at www.MillerWelds.com
SECTION 10 − MAINTENANCE AND TROUBLESHOOTING
10-1. SubArc System Help Codes
SubArc Interface
Digital Help Code
SubArc Power Source Status/Trouble Light
Fault
Description
. HELP will dis- . Each flash sequence will
play in the upper display,
and the code
number will
display in the
lower display.
be followed by a one second pause. The sequence will then repeat.
03
3 Slow
See 30
04
4 Slow
See 40
05
5 Slow
Primary Circuit Over
Temperature
Indicates unit has overheated. Unit has shutdown to allow fans to
lower temperature. Operation will continue after unit is within
normal temperature range.
06
6 Slow
See 60
26
2 Quick, 6 Slow
Button Stuck On System Interface Motor
Control
30
3 Quick
Stuck Contactor On
Power Source
Indicates stuck contactor on (Output On switch) the power
source. Fault will clear when panel switch is set to remote or
contactor is released.
32
3 Quick, 2 Slow
Coolant Flow Error
Indicates coolant input on TB2 in the SubArc Interface is not
connected to common on TB2 (see appropriate Interface OM).
Indicates button is stuck on the lower half of the SubArc Interface
upon start up, or Remote Start, Jog Up, or Jog Down is being
held low during start up. Fault will clear when button is released.
Check coolant flow and common connections.
Ensure sensor being used has a normally-open contact. Sensor
is only active if a Strip Drive 100 is connected.
40
4 Quick
Tach Error
Indicates tach error on motor. Check wire feed drive housing and
wire spool for obstructions. Make sure motor cable is not routed
with weld cable (If inching works properly, noise may be corrupting the tach signal). If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.
42
4 Quick, 2 Slow
Motor Error
Indicates motor overcurrent error on motor. Check wire feed
drive housing and wire spool for obstructions. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.
44
4 Quick, 4 Slow
Motor Low Bus
Indicates bus voltage in SubArc Interface is low. 24 VAC from
power source may be low if input primary line voltage is too low
or, for DC power sources, power source could be incorrectly
linked. Increase primary line voltage to at least 90% of specified
nominal voltage. Check for correct linking on DC power sources.
If this code continues to appear, contact nearest Factory Authorized Service Agent.
45
4 Quick, 5 Slow
Button Stuck On System Interface Digital
Display Board
48
4 Quick, 8 Slow
Trigger Fault
56
5 Quick, 6 Slow
Modbus Control Fault
Indicates PLC is enabling weld output, flux, or wire jog on initial
communication. Clear all control bits of MODBUS 101 to reset.
60
6 Quick
Memory Card Fault
Indicates unable to read memory card. Faulty memory card or
wrong format.
61
6 Quick, 1 Slow
File Read Error
Indicates faulty file on memory card.
62
6 Quick, 2 Slow
File Write Error
Indicates full or faulty memory card.
Indicates button is stuck on the digital interface upon power up.
Fault will clear when button is released.
Indicates an arc was not established with the specified time
(lesser of 8 seconds or 4 inches).
OM-265363 Page 37
. A complete Parts List is available at www.MillerWelds.com
10-1. SubArc System Help Codes (Continued)
SubArc Interface
Digital Help Code
SubArc Power Source Status/Trouble Light
Fault
Description
. HELP will dis- . Each flash sequence will
play in the upper display,
and the code
number will
display in the
lower display.
be followed by a one second pause. The sequence will then repeat.
63
6 Quick, 3 Slow
Invalid File
Indicates an invalid file on memory card. The system was able to
read the file; however, the contents of the file were invalid. Remove card or press any button to clear error.
64
6 Quick, 4 Slow
Memory Card Locked
Indicates a save was attempted to a locked card. This refers to
the physical switch on the memory card. Unlock the memory
card and try again. Try a different memory card. Remove card or
press any button to clear error. If this code continues to appear
on the display, contact the nearest Factory Authorized Service
Agent.
65
6 Quick, 5 Slow
Read Only File
Indicates a save was attempted to a file that has been marked
read−only. Check with the appropriate person to see if the attributes are read only for a reason (the attributes can be altered
using a PC). Use a different card. Remove card or press any
button to clear error.
66
6 Quick, 6 Slow
No Memory Card Detected
Indicates no memory card detected when a memory card operation was attempted. Insert a card or press any button to clear
error. Try a different memory card. If this code continues to appear on the display, contact the nearest Factory Authorized Service Agent.
67
6 Quick, 7 Slow
Unsupported Memory
Card Format
Indicates the file system is not supported. Memory card side is
too small.
71
7 Quick, 1 Slow
Invalid Model Type
If paralleling units, firmware in controlling power source does not
match firmware in the following power source. Update firmware
in both machines to the latest revision. If code continues to display, contact nearest Factory Authorized Service Agent.
72
7 Quick, 2 Slow
Invalid Motor Type
Indicates resistor is missing or improperly installed in motor cable. Make sure the motor being used is support by this system
(see Section4-4). Check motor to system interface control cable
connection and tighten if necessary (See Section 7-4). If this
code continues to appear on the display, contact the nearest
Factory Authorized Service Agent.
73
7 Quick, 3 Slow
Program Select Error
Indicates an invalid program has been selected using the program select inputs on the terminal strip. The program select is
not available because locks are enabled. This error will only
occur with program select mode enabled.
92
9 Quick, 2 Slow
Parallel Communication Loss
On trail unit − indicates communication cannot be established
with lead unit.
On lead unit − indicates communication was lost during welding.
93
9 Quick, 3 Slow
PLC Communication
Loss
Indicates communication with PLC was lost during welding.
94
9 Quick, 4 Slow
Automation Interface
Communication Loss
Indicates communication with Automation Interface was lost
during welding.
95
9 Quick, 5 Slow
Serial Communication
Loss
Indicates that the Process Control board lost communication with
the Motor Control board in the SubArc Interface.
97
9 Quick, 7 slow
Primary Communication Lost
Power source process control board cannot communicate with
the output controller. Power cycle unit. If problem persists, contact the nearest Factory Authorized Service Agent.
98
9 Quick, 8 Slow
Serial Communication
Loss
Indicates serial communication was initially made and is now
malfunctioning. Check SubArc Interface/power source control
cable connection and tighten if necessary. May appear normally
during firmware updates. If this code continues to appear on the
display, contact the nearest Factory Authorized Service Agent.
99
9 Quick, 9 Slow
Serial Communication
Malfunction
Indicates serial communication is malfunctioning. Check SubArc
Interface/power source control cable connection and tighten if
necessary. May appear normally during firmaware updates. If
this code continues to appear on the display, contact the nearest
Factory Authorized Service Agent.
OM-265363 Page 38
. A complete Parts List is available at www.MillerWelds.com
10-2. Power Source Routine Maintenance
!
Disconnect input power
before maintaining.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
. Maintain more often during
severe conditions.
l = Replace
Every
3
Months
nl Labels
Δ l Cracked Cables
l Cracked Parts
Every
3
Months
nΔ lCables And Cords
Every
3
Months
~:Weld Terminals
Every
6
Months
~:Blow out inside
10-3. Fuse F1
1
!
Disconnect and lockout/tagout input power before
checking or changing fuse.
Follow established procedures regarding the installation and removal of lockout/
tagout devices.
1
Fuse F1 (See Parts List For
Rating)
Fuse F1 protects control transformer from overload. If F1 opens, weld
output and fan motor stops. Replace F1.
Close and secure access door.
Tools Needed:
3/8 in.
802295
OM-265363 Page 39
. A complete Parts List is available at www.MillerWelds.com
10-4. Troubleshooting Table For Power Source
Trouble
No weld output; unit completely
inoperative; power switch light off.
Remedy
Place line disconnect device in On position (see Section 5-6).
Check for open line fuse(s), and replace if open (see Section 5-6).
Check for proper input power connections (see Section 5-6).
Check for proper jumper link position (see Section 5-5).
Check fuse F1, and replace if necessary (see Section 10-3).
No weld output; power switch light on.
Unit overheated. Allow unit to cool with fan On (see Section 4-7).
If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote
control (see Sections 6-1 and 8-1). If remote is not being used, place switch in On position (see Section 8-1).
Check, repair, or replace remote device.
No weld output; power switch light on;
fan off.
Check for proper input power connections (see Section 5-6).
Check for open line fuse(s), and replace if open, or reset circuit breaker (see Section 5-6).
Turn power switch off then back on. If no output condition remains, have Factory Authorized Service
agent check SCR’s.
Limited weld output and low
open-circuit voltage.
Check position of Remote Amperage/Voltage Control switch (see Section 8-1).
Check for open line fuse(s), and replace if open (see Section 5-6).
Check for proper input power connections (see Section 5-6).
Check for proper jumper link position (see Section 5-5).
Clean and tighten all weld output connections.
Unit provides only maximum or
minimum weld output.
Check position of Remote Amperage/Voltage Control switch (see Section 8-1).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 7-1).
Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
Clean and tighten all weld connections.
Check wire drive installation according to Owner’s Manual.
Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
No 24 volts AC output at Remote receptacle RC1.
Reset supplementary protector CB2.
Fan not operating. Note: fan only runs
when cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
OM-265363 Page 40
. A complete Parts List is available at www.MillerWelds.com
229895
Notes
MATERIAL THICKNESS GAUGE
OM-265363 Page 41
SECTION 11 − ELECTRICAL DIAGRAM
Figure 11-1. Circuit Diagram For DC 650/800 Models
OM-265363 Page 42
262523-E
OM-265363 Page 43
Figure 11-2. Circuit Diagram For DC 1000/1250 Models
OM-265363 Page 44
262521-E
OM-265363 Page 45
Notes
Welding Tip:
Securely connect work clamp to a clean area
close to the weld joint.
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)
18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)
1/8 in. (.125 in.)
3/16 in. (.188 in.)
1/4 in. (.25 in.)
5/16 in. (.313 in.)
3/8 in. (.375 in.)
1/2 in. (.5 in.)
Notes
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2019 Miller Electric Mfg. LLC
2019−01
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