Miller | MJ340509U | Owner Manual | Miller UNIVERSAL INVERTER RACK User manual

Miller UNIVERSAL INVERTER RACK User manual
OM-2810
220543N
2018−06
Processes
Multiprocess Welding
Description
Universal
Inverter Rack
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: MULTIPROCESS
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2017−06
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications For Racks Used With XMT 304 and XMT 350 Models . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Specifications For Racks Used With XMT 450 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Specifications For Racks Used With XMT 350 FieldPro Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Installing Welding Power Source Onto Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Welding Power Source Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Common Work Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Paralleling Welding Power Sources For SMAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Electrical Service Guide For XMT 304 4-Pack Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Electrical Service Guide For XMT 304 6-Pack Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Electrical Service Guide For XMT 450 4-Pack Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Electrical Service Guide For XMT 350 4-Pack Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Electrical Service Guide For XMT 350 / XMT 350 FieldPro 6-Pack Racks . . . . . . . . . . . . . . . . . . . . . .
5-12. Electrical Service Guide For XMT 350 FieldPro, Polarity Reversing 6-Pack Racks . . . . . . . . . . . . . .
5-13. Connecting 3−Phase Input Power To Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Line Fuse Size Requirements For XMT Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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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-2810 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-2810 Page 2
D Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use correct procedures and equipment of adequate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
OM-2810 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-2810 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-2810 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas couper ou souder des jantes ou des roues. Les pneus
peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
OM-2810 Page 6
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-2810 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-2810 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Notes
OM-2810 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back panel of the control box. Use rating label to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Specifications For Racks Used With XMT 304 and XMT 350 Models
Model
Rated
Output
XMT 304
1200 A @ 32
Voltage
Range in
CV Mode
Amperage
Range in CC
Mode
Maximum
Open-Circuit
Voltage DC
Amperes Input at Rated
Load Output, 60 Hz, Three
Phase
208
230
460
575
KVA
KW
N/A
122
75.6
N/A
48.8
46.4
N/A
183
113.4
N/A
73.2
69.6
230/460
VDC, 60% Duty
4-Pack Rack
Cycle
XMT 304
230/460
6-Pack Rack
1800 A @ 32
VDC, 60% Duty
Cycle
XMT 304
460/575
4-Pack Rack
1200 A @ 32
VDC, 60% Duty
Cycle
N/A
N/A
75.6
60.8
48.8
46.4
XMT 304
460/575
6-Pack Rack
1800 A @ 32
VDC, 60% Duty
Cycle
N/A
N/A
113.4
91.2
73.2
69.6
XMT 350
208-575
4-Pack Rack
1400 A @ 34
VDC, 60% Duty
Cycle
161.6
144.4
71.2
56.4
56.8
54.4
XMT 350
208-575
6-Pack Rack
2100 A @ 34
VDC, 60% Duty
Cycle
242.4
216.6
106.8
84.6
85.2
81.6
10-35 V
10-38 V
5-400 A
90 VDC
5-425 A
75 VDC
4-3. Specifications For Racks Used With XMT 450 Models
Model
Rated
Output
XMT 450
460*
4−Pack Rack
1800 A @ 38
VDC, 100%
Duty Cycle
XMT 450
575
4−Pack Rack
1800 A @ 38
VDC, 100%
Duty Cycle
Voltage Range
in CV Mode
10-38 V
Amperage Range
in CC Mode
15-600 A
* XMT 450 230/460 Volt Model−Operated on 460 volt input power only.
OM-2810 Page 10
Maximum OpenCircuit Voltage
DC
Amperes Input at
Rated Load Output, 60 Hz, Three
Phase
460
575
KVA
KW
110.4
N/A
88
75.6
N/A
97.6
97.6
76.8
90 VDC
4-4. Specifications For Racks Used With XMT 350 FieldPro Models
Model
Rated
Output
XMT 350
FieldPro
6-Pack Rack
2100 A @ 34
VDC, 60%
Duty Cycle
XMT 350
FieldPro Polarity
Reversing
6-Pack Rack
2100 A @ 34
VDC, 60%
Duty Cycle
Voltage
Range in CV
Mode
10-38 V
Amperage
Range in CC
Mode
Amperes Input at Rated
Load Output, 60 Hz,
Three Phase
Maximum
Open-Circuit
Voltage DC
5-425 A
208
230
460
575
KVA
KW
242.4
216.6
106.8
84.6
85.2
81.6
N/A
216.6
106.8
84.6
85.2
81.6
72 VDC
14-38 V
5-350 A
4-5. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored,
but is not intended to be used for welding outside during precipitation unless sheltered.
IP23 2014−06
Notes
OM-2810 Page 11
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Dimensions And Weight
7 ft (2.1 m)
minimum length
Empty Rack:
279 lb (127 kg)
7 ft (2.1 m)
minimum length
59 in.
(1500 mm)
43 in.
(1092 mm)
34-3/8 in.
(873 mm)
Movement
1
. Rated Capacity For Lifting Eyes:
Use lifting eye to move unit.
1500 lb (680 kg)
This rating is for the lifting
method shown above using both
lifting eyes. DO NOT use just
a single lifting eye to move unit.
2
Lifting Eyes
Lifting Forks
If using lifting forks, be sure forks
are fully inserted.
1
2
801697-D
OM-2810 Page 12
5-2. Installing Welding Power Source Onto Rack
Have only qualified persons make
this installation.
!
Turn Off welding power
sources before inspecting
or installing rack.
For XMT 304/350 Models
1
Welding Power Source
Position welding power source
onto rack shelf so threaded holes in
feet are over correct holes in shelf
on rack (see illustration). Welding
power source front panel should
face side of rack with isolated terminal on base as shown.
2
Securing Bolts And Hardware
Install supplied bolts through rack
shelf into welding power source
feet and tighten.
For XMT 450 Models
1
1
Position welding power source
onto rack shelf so the nuts inserted
in the base of th welder align with
correct holes in shelf on rack (see
illustration). Welding power source
front panel should face side of rack
with isolated terminal on base as
shown.
2
For XMT 304/350 And XMT 450 Models
Welding Power Source
For XMT 304/350 Models Only
. The factory-supplied mounting
hardware is for XMT 304/350
models only. Do not attempt to
use this hardware when installing a XMT 450.
Install user-supplied 1/4 in. mounting bolt through holes in welding
power source base and rack shelf
and tighten user-supplied hardware to secure in place.
Holes 1 And 5
Holes 7 And 8
Holes 10 And 14
Mounting Hole
Pattern For XMT
304/350 Models
(Both Shelves)
Holes 3 And 6
Holes 9 And 12
Mounting
Shelves
Mounting Hole
Pattern For
XMT 450 Models
(Both Shelves)
ST-801192 / 801698-A / 802537-A / 801697-D
OM-2810 Page 13
5-3. Welding Power Source Input Power Connections
1
1
2
3
Side View
7
5
4
6
Tools Needed:
Ref. 221549 / 220156 / 804787-C / 801702-B
!
Disconnect input power to rack before
working on wiring for any welding
power source.
Have only qualified persons make this installation.
1
Control Box
Open access door on front of control box.
2
3
rack is numbered. The numbers on the control
box access door refer to the similarly located
strain relief connectors and fuse block inside
the control box. Insert power cord into strain
relief with number matching location of welding power source on rack.
4
Grounding Conductor − Green Or Green
With Yellow Stripe(s)
5
Grounding Terminal
Strain Relief Connector
Welding Power Source Input Power
Cord
Each welding power source location on the
OM-2810 Page 14
Install grounding conductor to grounding
terminal.
6
Input Conductors
7
Power Fuse Block Terminals
. When installing conductors from the weld-
ing power source, torque the Power fuse
block terminals and grounding terminal to
45 in.-lbs (5.1 N·m).
Install input conductors from welding power
source to Power fuse block nearest entry for
input conductors.
Tighten strain relief connector. Close and secure access door.
5-4. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
150 ft
(45 m)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
1/0 (60)
1/0 (60)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
150
3 (30)
3 (30)
200
3 (30)
2 (35)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
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)
1500
600 (300)
750 (400)
1000 (500)
2x750 (2x400)
1750
750 (400)
1000 (500)
2x750 (2x400)
2x1000 (2x500)
2000
800 (400)
1000 (500)
2x750 (2x400)
2x1000 (2x500)
* 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
Notes
OM-2810 Page 15
5-5. Common Work Connections
1
3
4
3
2
5
5
4
Tools Needed:
801700-E
3/4 in.
!
!
Turn Off welding power sources by
placing Power circuit breakers in the
Off position before making any weld
output connections.
See ANSI Z49.1 and OSHA Title 29,
Chapter XVII, Part 1910, Subpart Q
(addresses at beginning of manual).
!
1
Inadequate work cable connections
can cause serious damage to input
power service and create a hazardous
condition. Connect an electrical cable
of adequate size between the isolated
terminal and the workpiece whenever
the isolated terminal is used.
4
Positive (+) Weld Output Cables
Use lugs of proper amperage capacity and
hole size for connecting to isolated terminal.
Isolated terminal is 1/2 in. (12.7 mm) in
diameter.
!
Do not handle or come in contact with
two live electrodes at the same time.
Determine cable lengths and sizes according
to welding power source Owner’s Manual.
!
Arcing can burn skin or damage electrical equipment. Do not change position of the welding cable connectors
while welding.
2
Isolated Terminal
3
Negative (−) Weld Output Cables
!
Be sure the connectors are secure in
receptacles before welding.
OM-2810 Page 16
Determine cable sizes according to welding
power source Owner’s Manual. Cable must
reach from negative (−) output receptacle to
isolated terminal.
Common Negative (−) Weld Output
Cable
Cable must be able to carry combined weld
output of all welding power sources using
common work connections. Use Section 5-4
to select proper cable size.
5
Terminal Lugs
XMT only: For Electrode Negative, reverse
cable connections. Positive (+) weld output
cables connect to isolated terminal, negative
(−) weld output cables go to electrode. Common weld output cable is positive.
. FieldPro units do not require swapping
cables for electrode negative.
5-6. Paralleling Welding Power Sources For SMAW
. This section is for XMT units only.
. Do Not connect PipeWorx 350 FieldPro units in
parallel. Paralleling can damage FieldPro units.
1
1
4
4
2
1
!
Securely cover connection
with proper insulating
3
material.
4
ST-801701
!
!
Turn Off welding power sources by
placing Power circuit breakers in the
Off position before making any weld
output connections.
See ANSI Z49.1 and OSHA Title 29,
Chapter XVII, Part 1910, Subpart Q
(addresses at beginning of manual).
!
Do not handle or come in contact with
two live electrodes at the same time.
!
Arcing can burn skin or damage electrical equipment. Do not change position of the welding cable connectors
while welding.
!
Be sure the connectors are secure in
receptacles before welding.
Inadequate work cable connections
can cause serious damage to input
power service and create a hazardous
condition. Connect an electrical cable
of adequate size between the isolated
terminal and the workpiece whenever
the isolated terminal is used.
2
Set the Amperage/Voltage control on all paralleled welding power sources to the same
value. The isolated terminal may be used as
a common connection point if no other connections are made to it.
4
!
The procedure shown is for Electrode Positive welding connections.
1
Weld Output Cables
Determine cable sizes according to welding
power source Owner’s Manual. Cables must
reach cable connection point. Cables connected together must be the same polarity.
Connection Point
Cover with proper insulating material after
making connections.
3
Terminal Lugs
Use lugs of proper amperage capacity and
hole size for connection.
Common Weld Output Cable
Cable must be able to carry combined weld
output of all welding power sources connected in parallel. Use Section 5-4 to select
proper cable size.
XMT only: For Electrode Negative, reverse
cable connections. Positive (+) weld output
cables connect to work, negative (−) weld
output cables go to electrode.
. FieldPro units do not require swapping
cables for electrode negative.
OM-2810 Page 17
Elec Serv 2017-01
5-7. Electrical Service Guide For XMT 304 4-Pack Racks
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be available.
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.
Installation must meet all National and Local Codes − have only qualified persons make this installation.
60 Hz Three Phase
Input Voltage (V)
Rated Maximum Supply Current I1max (A)
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In
230
460
170.8
98
93.6
53.6
Amperes1
Time-Delay Fuses2
200
110
Normal Operating Fuses 3
250
125
3 (30)
6 (16)
127(39)
171 (52)
4 (25)
6 (16)
Min Input Conductor Size In AWG (mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG (mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
Elec Serv 2017-01
5-8. Electrical Service Guide For XMT 304 6-Pack Racks
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be available.
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.
Installation must meet all National and Local Codes − have only qualified persons make this installation.
60 Hz Three Phase
Input Voltage (V)
230
460
256.2
147
140.4
80.4
Time-Delay Fuses2
300
175
Normal Operating Fuses 3
350
200
1/0 (50)
4 (25)
165 (50)
277 (84)
3 (30)
6 (16)
Rated Maximum Supply Current I1max (A)
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In
Min Input Conductor Size In AWG
Amperes1
(mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
OM-2810 Page 18
5-9. Electrical Service Guide For XMT 450 4-Pack Racks
Elec Serv 2017−01
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be available.
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.
Installation must meet all National and Local Codes − have only qualified persons make this installation.
60 Hz Three Phase
Input Voltage (V)
460
575
Rated Maximum Supply Current I1max (A)
138.8
118
Maximum Effective Supply Current I1eff (A)
116.4
98.8
Time-Delay Fuses2
150
125
Normal Operating Fuses 3
200
175
1 (35)
3 (30)
365 (111)
439 (134)
6 (16)
6 (16)
Max Recommended Standard Fuse Rating In Amperes1
Min Input Conductor Size In AWG (mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
Elec Serv 2017-01
5-10. Electrical Service Guide For XMT 350 4-Pack Racks
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be available.
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.
Installation must meet all National and Local Codes − have only qualified persons make this installation.
60 Hz Three Phase
Input Voltage (V)
208
230
460
575
Rated Maximum Supply Current I1max (A)
206
186
90.4
72
125.2
112.8
54.8
43.6
Time-Delay Fuses2
250
225
110
90
3
300
250
125
100
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In Amperes1
Normal Operating Fuses
Min Input Conductor Size In AWG
(mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG (mm2) 4
1 (35)
2 (35)
6 (16)
8 (10)
134 (41)
134 (41)
228 (70)
228 (70)
4 (25)
4 (25)
6 (16)
8 (10)
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
OM-2810 Page 19
5-11. Electrical Service Guide For XMT 350 / XMT 350 FieldPro 6-Pack Racks
Elec Serv 2017−01
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be available.
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.
Installation must meet all National and Local Codes − have only qualified persons make this installation.
60 Hz Three Phase
Input Voltage (V)
208
Rated Maximum Supply Current I1max (A)
230
460
575
309
279
135.6
108
187.8
169.2
82.2
65.4
Time-Delay Fuses2
350
300
150
125
Normal Operating Fuses 3
450
400
200
150
Min Input Conductor Size In AWG (mm2) 4
3/0 (95)
2/0 (70)
4 (25)
4 (25)
Max Recommended Input Conductor Length In Feet (Meters)
167 (51)
167 (51)
237 (72)
371 (113)
2 (35)
3 (30)
6 (16)
6 (16)
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In Amperes1
Min Grounding Conductor Size In AWG
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
5-12. Electrical Service Guide For XMT 350 FieldPro, Polarity Reversing
6-Pack Racks
Elec Serv 2017−01
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be available.
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.
Installation must meet all National and Local Codes − have only qualified persons make this installation.
60 Hz Three Phase
Input Voltage (V)
230
460
575
Rated Maximum Supply Current I1max (A)
279
135.6
108
169.2
82.2
66
Time-Delay Fuses2
300
150
125
3
400
200
150
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In
Amperes1
Normal Operating Fuses
Min Input Conductor Size In AWG
(mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG (mm2) 4
2/0 (70)
4 (25)
4 (25)
167 (51)
237 (72)
371 (113)
3 (30)
6 (16)
6 (16)
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
OM-2810 Page 20
Notes
OM-2810 Page 21
5-13. Connecting 3−Phase Input Power To Rack
3
GND/PE Earth Ground
12
11
9
L1
5
L2
8
L3
10
2
3
1
2
7
6
8
3
5
4
Ref.803766-C / 801702-B / 804787-C / input3 2015−01
OM-2810 Page 22
5-13. Connecting 3-Phase Input Power To Rack (Continued)
!
!
Installation must meet all National
and Local Codes − have only qualified
persons make this installation.
Control Box Input Power Connections
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
Open access door.
Disconnect Device Input Power Connections
3
9
!
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
Sections 5-7 thru 5-12. Conductors must
comply with national, state, and local electrical codes. If applicable, use lugs of proper
amperage capacity and correct hole size.
2
Close and secure access door on control
box.
Control Box
Strain Relief (Customer Supplied)
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)
10 Disconnect Device (Supply) Grounding
Terminal
11 Disconnect Device Line Terminals
4
Control Box Grounding Terminal
5
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect green or green/yellow grounding
conductor to control box grounding terminal
first.
Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.
6
Input Terminal Block
7
Control Box Line Terminals
8
Input Conductors L1 (U), L2 (V) And L3
(W)
Connect input conductors L1 (U), L2 (V) and
L3 (W) to control box line terminals.
12 Over-Current Protection
Select type and size of over-current protection using Sections 5-7 thru 5-12 (fused disconnect switch shown).
Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.
input3 2015−01
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-2810 Page 23
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
l = Replace
l Unreadable Labels
n~ Weld Terminals
n~ Weld Terminals
nl Weld Cables
nl Cords
nl Gun Cables
~Weld Connections
nTighten Weld Connections
Every
3
Months
nl Torch Body
6-2. Overload Protection
1
2
Control Box
3-Phase Fuse Block
Each Power fuse block protects the
welding power source connected to
it from overload.
3
4
Fuses
Fuse Indicator Window
If fuse(s) in fuse block opens, the
matching welding power source
shuts down. To check fuse block,
place main disconnect switch in
OFF position.
Open control box door, check fuse
block of non−operational machine.
1
An open fuse will show as a black
spot in the indicator window of the
fuse.
2
Replace fuse per Section 6-3 for
machine type.
3
4
Ref. 221549-A / 804787-C / 220156-A
OM-2810 Page 24
6-3. Line Fuse Size Requirements For XMT Models
220 551-C
6-4. Troubleshooting
Trouble
No weld output from any welding
power sources; units completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-13).
Check and replace line fuse(s), if necessary (see Sections 6-2 and 6-3).
Check for proper input power connections to rack (see Section 5-13).
No weld output from one welding power source.
Check fuses in applicable fuse block (see Section 6-2).
Check for proper input power connections to welding power source (see Section 5-3).
Check applicable welding power source according to its Owner’s Manual.
Notes
OM-2810 Page 25
SECTION 7 − ELECTRICAL DIAGRAMS
220773-B
Figure 7-1. Circuit Diagram For Control Panel In 4-Pack Racks
220776-C
Figure 7-2. Circuit Diagram For Control Panel In 6-Pack Racks
OM-2810 Page 26
Notes
OM-2810 Page 27
SECTION 8 − PARTS LIST
. Hardware is common and
6
not available unless listed.
5
2
3
Fig 8-2
1
9
8
10
4
Fig 8-3
12
7
11
804764-B
Figure 8-1. Main Assembly
OM−2810 Page 28
Item
No.
Part
No.
Description
Figure 8-1. Main Assembly
. . 1 . . . . . . . . . . . . . . 183386 . .
. . 2 . . . . . . . . . . . . +183385 . .
. . 3 . . . . . . . . . . . . +221549 . .
. . 3 . . . . . . . . . . . . +221553 . .
. . 4 . . . . . . . . . . . . . . 220548 . .
. . 5 . . . . . . . . . . . . . . 183699 . .
. . 6 . . . . . . . . . . . . . . 134327 . .
. . 7 . . . . . . . . . . . . . . 149232 . .
. . 8 . . . . . . . . . . . . . . 151488 . .
. . 9 . . . . . . . . . . . . . . 251131 . .
. . 10 . . . . . . . . . . . . . 221552 . .
. . 11 . . . . . . . . . . . . . 255996 . .
. . 12 . . . . . . . . . . . . . 209479 . .
. . . . . . . . . . . . . . . . . . . 274015 . .
.............................
. . . . . . . . . . . . . . . . . . . 274017 . .
.............................
. . . . . . . . . . . . . . . . . . . 219487 . .
. . . . . . . . . . . . . . . . . . . 263090 . .
. . . . . . . . . . . . . . . . . . . 263092 . .
. . . . . . . . . . . . . . . . . . . 277891 . .
. . . . . . . . . . . . . . . . . . . 277892 . .
Quantity
6-Pack 4-Pack
Frame, Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Roof, Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Control Box, Rack 6-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
Control Box, Rack 4-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket Assy, MTG Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Label, Warning Do Not Stack Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Label, Warning General Precautionary Static and Wire FE . . . . . . . . 2 . . . . 2
Label, Number 0 Through 9 1in High White On Clear . . . . . . . . . . . . 6 . . . . 4
Label, Isolated Terminal-See Owners Manual . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Cover, Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Label, Instruction Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Caster, Fixed 5.000 In Urethane 2.000 In Wide . . . . . . . . . . . . . . . . . 2 . . . . 2
Caster, Swivel 5.00 In Urethane W/Brake 2.000 In Wide . . . . . . . . . 2 . . . . 2
Weld Cable, 2/0 Blk W/Tweco Bev & Term 1/2in 32in
(Not Used On XMT 450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 2
Weld Cable, 2/0 Blk W/Tweco Bev & Term 1/2in 46in
(Not Used On XMT 450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 2
Cable, Power (XMT 450 4-Pack Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bushing, Strain Relief .709/.984 Id X1.650 Mtg Hole (XMT 450 4-Pack Only) 4
Nut, 1.250 Npsm Knurled (XMT 450 4-Pack Only) . . . . . . . . . . . . . . . . . . . . . . 4
Cable, Weld No 4/0 Blk W/Ring Term 2ft (XMT 450 4-Pack Only) . . . . . . . . . 2
Cable, Weld No 4/0 Blk W/Ring Term 3ft (XMT 450 4-Pack Only) . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
OM-2810 Page 29
. Hardware is common and
12
not available unless listed.
14
13
7
11
10
8
1
9
6
2
5
3
4
Figure 8-2. Control Box
Notes
OM−2810 Page 30
804765-B
Item
No.
Part
No.
Description
Figure 8-2. Control Box (Fig 8-1 Item 3)
. . 1 . . . . . . . . . . . . +221550
. . 2 . . . . . . . . . . . . . 221551
. . 3 . . . . . . . . . . . . . 220159
. . 4 . . . . . . . . . . . . . 183836
. . 5 . . . . . . . . . . . . . 220160
. . 6 . . . . . . . . . . . . . 183837
. . 7 . . . . . . . . . . . . . 215980
. . 8 . . . . . . . . . . . . . 234126
. . 9 . . . . . . . . . . . . . 220549
. . 10 . . . . . . . . . . . . 183167
. . 11 . . . . . . . . . . . . 253765
. . 12 . . . . . . . . . . . . 183842
. . 13 . . . . . . . . . . . . 220161
. . 14 . . . . . . . . . . . . 603122
. . . . . . . . . . . . . . . . . . 220550
. . . . . . . . . . . . . . . . . . 183698
. . . . . . . . . . . . . . . . . . 149232
. . . . . . . . . . . . . . . . . . 155436
. . . . . . . . . . . . . . . . . . 220551
. . . . . . . . . . . . . . . . . . 229434
. . . . . . . . . . . . . . . . . . 229435
. . . . . . . . . . . . . . . . . . 229436
. . . . . . . . . . . . . . . . . . 229437
. . . . . . . . . . . . . . . . . . 220773
. . . . . . . . . . . . . . . . . . 220774
. . . . . . . . . . . . . . . . . . 220776
. . . . . . . . . . . . . . . . . . 220777
. . . . . . . . . . . . . . . . . . 220161
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
6-Pack
4-Pack
Distribution Box, W/ Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Mounting Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Holder, Fuse Cube 60A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . 12
Distribution Blk, Power 600V Black 285Amp . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Cover, Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Block, Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole . . . . . . . . . . . 6 . . . . . . . 4
Nut, Conduit 1.000 Npt Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . 4
Lug, Univ W/Scr 600v 1/0-14 Wire (2) .250 Dia Mtg . . . . . . . . . . . 6 . . . . . . . 4
Conn, Clamp Cable 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Support, Lid Self Balancing 30−60 Lbs Antique Coppe . . . . . . . . . 1 . . . . . . . 1
Catch, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Blank, Knockout Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Weatherstripping, Adh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.333ft . . 5.333ft
Label, Caution Incorrect Voltage Can Damage Etc . . . . . . . . . . . . 2 . . . . . . . 2
Label, Warning Electric Shock Can Kill/Close Door . . . . . . . . . . . . 1 . . . . . . . 1
Label, Number 0 Thur 9 1 In High White On Clear . . . . . . . . . . . . . 6 . . . . . . . 4
Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Label, Fuse Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Label, Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Label, Fuse F12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Label, Fuse F18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
Label, Terminal Block Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1
Ckt, Universal Rack (4 Pack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Wiring Diagram, Unit Universal Rack (4 Pack) . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ckt, Universal Rack (6 Pack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
Wiring Diagram, Unit Universal Rack (6 Pack) . . . . . . . . . . . . . . . . 1 . . . . . . . .
Blank, Knockout Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
OM-2810 Page 31
. Hardware is common and
not available unless listed.
10
9
1
2
3
4
5
6
7
8
Ref. 804763-B
Figure 8-3. Bracket Assembly
Item
No.
Part
No.
Description
Quantity
Figure 8-3. Bracket Assembly (Fig 8-1 Item 4)
. . 1 . . . . . . . . . . . . . . 602216 . . Washer, Lock .502idx0.879odx.151T Stl Pld Split.500 . . . . . . . . . . . . . . . . . . 6
. . 2 . . . . . . . . . . . . . . 602247 . . Washer, Flat .531idx1.062odx.095T Stl Pld Ansi.500 . . . . . . . . . . . . . . . . . . 12
. . 3 . . . . . . . . . . . . . . 601879 . . Nut, 500−13 .75 Hex .44H Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 4 . . . . . . . . . . . . . . 220164 . . Insulator, Stud Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 048389 . . Screw, 010−32x .75 Hexwhd.40d Stl Pld Slf Fmg Sems . . . . . . . . . . . . . . . . 6
. . 6 . . . . . . . . . . . . . . 251132 . . Bracket, Mtg Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 231174 . . Screw, 500−13x2.00 Hex Hd−Pln Stl Pld Full Thread . . . . . . . . . . . . . . . . . . 2
. . 8 . . . . . . . . . . . . . . 601847 . . Nut, 010−32 .38 Hex .24H Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . 6
. . 9 . . . . . . . . . . . . . . 601976 . . Screw, 500−13x1.50 Hex Hd−Pln Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 10 . . . . . . . . . . . . . 231172 . . Bus Bar, Stud Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM−2810 Page 32
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
Notes
Effective January 1, 2018
(Equipment with a serial number preface of MJ or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective date of 6. 90 Days — Parts
this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
* Canvas Covers
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
* Induction Heating Coils and Blankets, Cables, and
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
Non-Electronic Controls
FITNESS.
* M-Guns
Within the warranty periods listed below, Miller will repair or replace any
warranted parts or components that fail due to such defects in material
* MIG Guns, Subarc (SAW) Torches, and External
or workmanship. Miller must be notified in writing within thirty (30) days
Cladding Heads
of such defect or failure, at which time Miller will provide instructions on
* Remote Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted
* Replacement Parts (No labor)
as an online warranty claim, the claim must include a detailed
* Spoolmate Spoolguns
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.
Miller shall honor warranty claims on warranted equipment listed below
in the event of such a failure within the warranty time periods. All
warranty time periods start on the delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Auto-Darkening Weld Masks (No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL AND
INDUSTRIAL USERS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at Miller’s option,
either: (1) repair; or (2) replacement; or, if approved in writing by
Miller, (3) the pre-approved cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon use).
Products may not be returned without Miller’s written approval.
Return shipment shall be at customer’s risk and expense.
The above remedies are F.O.B. Appleton, WI, or Miller’s authorized
service facility. Transportation and freight are the customer’s
responsibility. TO THE EXTENT PERMITTED BY LAW, THE
REMEDIES HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES REGARDLESS OF THE LEGAL THEORY. IN NO
EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT,
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT) REGARDLESS OF THE LEGAL
THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY MILLER.
Some US states do not allow limiting the duration of an implied
warranty or the exclusion of certain damages, so the above
limitations may not apply to you. This warranty provides specific
legal rights, and other rights may be available depending on your
state. In Canada, some provinces provide additional warranties or
remedies, and to the extent the law prohibits their waiver, the
limitations set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary by province.
miller_warr 2018-01
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
© 2018 Miller Electric Mfg. LLC
2018−01
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