Miller | MH052516U | Owner Manual | Miller XMT 450 CC/CV WITH ARCREACH User manual

Miller XMT 450 CC/CV WITH ARCREACH User manual
OM-273025D
2016−11
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMT 450 CC/CV
R
With ArcReach
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: MULTIPROCESS
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Features And Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Selecting Input Voltage (230/460 Volt Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. (Optional) 115 Volts AC Duplex Receptacle And Supplementary Protectors . . . . . . . . . . . . . . . . . . . .
5-8. Optional Gas Valve Operation And Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Associating ArcReach Device To ArcReach Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − GTAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Typical Connection For GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Lift-Arc TIG Welding Mode - GTAW Lift-Arc - Output ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. TIG Welding Mode - GTAW Process - Remote ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 8 − GMAW/FCAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . .
8-2. MIG Welding Mode - GMAW/FCAW Process - Remote ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW/FCAW-S Process . . . . . . . . . . . . . .
8-4. V-Sense Feeder Welding Mode - GMAW/FCAW/FCAW-S Output ON . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − SMAW/CAC-A OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Typical Connection For SMAW And CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Stick Welding Modes - SMAW EXX18/SMAW EXX10/CAC-A Gouge - Output ON . . . . . . . . . . . . . . .
9-3. Low Open Circuit Voltage (OCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Alternate Configuration Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460 Volt Models . . . . . . .
10-4. Removing Right Side Panel and Measuring Input Capacitor Voltage In 575 Volt Models . . . . . . . . . .
10-5. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
31
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34
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35
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37
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-273025 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-273025 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-273025 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-273025 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
OM-273025 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surOM-273025 Page 6
chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par
exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
OM-273025 Page 7
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-273025 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
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
OM-273025 Page 9
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Do not use one handle to lift or support unit.
Safe31 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
V
V
>60sec
= < 60°
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 60 seconds
after power is turned off before working on unit, OR check input capacitor voltage, and be sure it is near 0 before touching any parts.
V
Safe43 2012−05
Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
OM-273025 Page 10
3-2. Miscellaneous Symbols And Definitions
A
V
Amperage
Voltage
Three Phase
%
Percent
Negative
Output
Single Phase
On
Positive
Variable
Inductance
Remote
Gas Metal Arc
Welding (GMAW)
Arc Force
(DIG)
Voltage Input
Flux Cored Arc
Welding (FCAW)
Line Connection
Shielded Metal
Arc Welding
(SMAW)
Off
Air Carbon Arc
Cutting (CAC-A)
Flux Cored Arc
Welding - Self
Shielded
(FCAW-S)
Gas Tungsten Arc
Welding (GTAW)
Setup
(Arc Control)
Lift-Arc Operation
(GTAW)
Notes
OM-273025 Page 11
SECTION 4 − SPECIFICATIONS
4-1. Features And Benefits
LVC Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input power fluctuation.
Wind Tunnel Technology circulates air over components that require cooling, not over electronic circuitry, which
reduces contaminants and improves reliability in harsh welding environments.
Fan-On-Demand cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through the machine.
Thermal Overload Protection automatically shuts down the unit, only when necessary to prevent damage to internal
components if the duty cycle is exceeded or air flow and cooling are restricted (see Section 4-7).
Auto Remote Sense enables the unit to automatically sense the connection of a remote control. Operation of the
remote control is dependent on the Mode Switch Setting (see Section 6-2).
Lift-Arc TIG starts provide a contamination free weld without the use of high frequency in the Lift-Arc TIG Welding
Mode (see Section 7-2).
ArcReach) Remote Control allows remote control of various functions of the power source by an ArcReach
compatible wire feeder or remote control device, without the use of a control cable (see Section 6-3). Operation of
the ArcReach feature is dependent on the Mode Switch Setting (See section pertaining to process being used).
Low OCV Operation This unit is factory configured to provide low Open Circuit Voltage (OCV) (see Section 9-3).
4-2. Arc Controls
Arc Control in Stick Mode allows the arc characteristics, soft versus stiff, to be changed for specific applications
and electrodes in Stick Welding Mode (see Section 9-2).
Arc Control in Wire Mode influences the arc stiffness, bead width and appearance, and puddle fluidity in MIG and
V-Sense Feeder Welding Modes (see Sections 8-2 and 8-4).
Programmable Hot Start Time allows the start amperage time to be changed for Stick Welding Modes. This helps
eliminate electrode sticking during arc initiation. (see Section 9-2).
4-3. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
4-4. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-9 and 5-10 for information on connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
A. 230/460 Volt Model Specifications
Input
Power
Three
Phase
Rated Welding
Output
450 A @ 38 Volts DC,
100% Duty Cycle
Amperage
Range
15 − 600
Voltage
Range
10 − 38
Maximum
OpenCircuit
Voltage
DC
Amperes Input At Rated
Load Output 60 Hz,
Three-Phase
90
KVA
KW
230 V
460 V
230/460
230/460
51.0
(0.33*)
27.6
(0.21*)
22.0
(0.16*)
18.9
(0.11*)
*While idling with fan on
B. 575 Volt Model Specifications
Input
Power
Rated Welding
Output
Three
Phase
450 A @ 38 Volts DC, 100%
Duty Cycle
*While idling with fan on
OM-273025 Page 12
Amperage
Range
15 − 600
Voltage
Range
10 − 38
Maximum
OpenCircuit
Voltage DC
90
Amperes Input
At Rated Load
Output 60 Hz,
Three-Phase
KVA
KW
575 V
575
575
24.4
(0.16*)
24.4
(0.16*)
19.2
(0.11*)
4-5. Dimensions and Weight
Hole Layout Dimensions
A
8-11/16 in. (221 mm)
B
11-3/8 in. (289 mm)
C
15-3/4 in. (400 mm)
D
22-7/16 in. (570 mm)
26.8 in.
(681 mm)
17.2 in.
(437 mm)
D C
E
2-3/4 in. (70 mm)
F
3-3/8 in. (86 mm) Dia.
G
1/4-20 UNC 2B Thread
14.5 in.
(368 mm)
F
Weight
E
G
109 lb (49.4 kg)
A
B
Ref. 252018-B
4-6. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored,
but is not intended to be used for welding outside during precipitation unless sheltered.
IP23 2014−06
B. Temperature Specifications
Operating Temperature Range
Storage Temperature Range
14 to 104°F (−10 to 40°C)
−4 to 131°F (−20 to 55°C)
Temp_2016- 07
Notes
OM-273025 Page 13
4-7. Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 450 Amperes
60% Duty Cycle At 580 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − SA-181 560 / 250 541-A
OM-273025 Page 14
4-8. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of welding
power source. Curves of other settings fall between curves shown.
CC Mode
100
90
80
VOLTAGE
STICK
MAX
STICK
80A
70
60
TIG
REMOTE
50
TIG
MAX
TIG
SCRATCH
40
30
20
TIG
MIN
10
0%
25%
ARC CONTROL (DIG)
50%
75%
100%
0
0
100
200
300
400
500
600
AMPERAGE
CV MODE
100
VOLTAGE
80
60
MAX
40
20
MIN
0
0
100
200
300
400
500
600
700
AMPERAGE
252 918-A / 252 919-A
OM-273025 Page 15
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
!
2
Do not move or operate unit
where it could tip.
2
OR
3
1
Location And Airflow
4
18 in.
(460 mm)
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Lifting Forks
Extend forks beyond opposite side
of unit.
2
Lifting Handles
Use handles to lift unit.
3
Hand Cart
Use cart or similar device to move
unit.
4
18 in.
(460 mm)
Line Disconnect Device
Locate unit near correct input
power supply.
loc_med 2015-04
Notes
OM-273025 Page 16
5-2. Selecting Input Voltage (230/460 Volt Models Only)
!
. Be sure to reinstall all four screws
securing relinking board in place.
Turn Off welding power
source, disconnect input
power, and check voltage
on input capacitors according to Section 10-3 before
proceeding.
Check input voltage available at
site.
1
Voltage Selection View
Window
Check voltage selected in unit.
Changing selection is only necessary if selected value does not
match available input voltage.
1
2
3
4
5
Relinking Board PC6
Mounting Screws
Receptacle RC8 (Connection
For 230 VAC Input Power)
Receptacle RC7 (Connection
For 460 VAC Input Power)
Move relinking board as needed
and connect plug PLG4 (in unit) to
RC8 or RC7 according to input
power voltage.
2
3
4
3
5
Tools Needed:
5/16 in.
252018-B / 252019-A
OM-273025 Page 17
5-3. 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)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02
5-4. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
. See Section 5-5 for information on
connecting to weld output terminals, and Sections 7-1 thru 9-1 for
standard connection diagrams.
1
2
Ref. 273 528-B / output term1 2015−02
OM-273025 Page 18
5-5. Connecting Weld Output Cables
4
1
Do not place
anything between
weld cable terminal
and copper bar.
2
Tools Needed:
3
3/4 in. (19 mm)
Incorrect Installation
!
Turn off power before connecting to
weld output terminals.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
1 Weld Output Terminal
2 Supplied Weld Output Terminal Nut
3 Weld Cable Terminal
4 Copper Bar
Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld
803 778-B
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar. Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
5-6. Remote 14 Receptacle Information
A
B
K
J
Socket*
Socket Information
A
24 volts AC. Protected by supplementary protector CB2.
B
Contact closure to A completes 24 volts AC contactor control circuit.
C
Output to remote control; +10 volts DC in MIG
mode. 0 to +10 volts DC in other modes.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from remote control.
M
CC/CV select 0 to +10 volts DC.
A/V
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 arc volts.
G
Circuit common for 24 volt AC circuit.
K
Chassis common.
24 VOLTS AC
I
H
C L N
D M
G
E F
Ref. 252018-B
REMOTE
CONTROL
GND
*The remaining sockets are not used.
OM-273025 Page 19
5-7. (Optional) 115 Volts AC Duplex Receptacle And Supplementary Protectors
1
2
(Optional) 115 V 10 Amp AC
Receptacle
Supplementary Protector CB1
CB1 protects (Optional) 115V 10
Amp AC receptacle.
1
2
3
3
Supplementary Protector CB2
CB2 protects 24 volts AC portion of
Remote 14 receptacle from
overload.
Press button to reset supplementary protector.
4
USB Connector
4
250028-C
Notes
OM-273025 Page 20
5-8. Optional Gas Valve Operation And Shielding Gas Connection
Obtain gas cylinder and chain to
running gear, wall, or other stationary support so cylinder cannot fall
and break off valve.
1
2
Cylinder
Regulator/Flowmeter
Install so face is vertical.
3
Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Obtain and install gas
hose.
4
4
5
2
Gas In Fitting
Gas Out Fitting
The Gas In and Gas Out fittings
have 5/8-18 right-hand threads.
Obtain proper size, type, and length
hose and make connections as follows:
Connect hose from shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect hose coupler to torch.
Connect one end of gas hose to
hose coupler. Connect remaining
end of gas hose to Gas Out fitting.
Operation
The gas solenoid controls gas flow
during the TIG process as follows:
Remote TIG
1
3
Gas flow starts with remote contactor on.
Gas flow stops at end of post−flow
if current was detected, or with remote contactor off if no current was
detected.
Lift−Arc TIG
Gas flow starts when tungsten
touches work (touch sensed).
Gas flow stops at end of post−flow.
Post−flow time is factory set to 5
seconds per 100 amps of weld current. The minimum post−flow time
is 5 seconds. The maximum post−
flow is 20 seconds (post flow settings are not adjustable by the end
user).
5
Ref. 250029-C
OM-273025 Page 21
5-9. Electrical Service Guide
Elec Serv 2015−05
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
60 Hz Three Phase
Input Voltage (V)
230
460
575
Rated Maximum Supply Current I1max (A)
67.3
34.7
29.5
Maximum Effective Supply Current I1eff (A)
56.0
29.1
24.7
Time-Delay Fuses2
60
30
30
3
80
40
35
6
10
10
159
(48)
271
(83)
415
(126)
8
10
10
Max Recommended Standard Fuse Rating In Amperes1
Normal Operating Fuses
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
Notes
OM-273025 Page 22
Notes
OM-273025 Page 23
5-10. Connecting Input Power
3
= GND/PE
Earth Ground
9
11
8
7
6
L1 L2
L3
L1
3
5
L2
7
L3
10
1
1
2
5
4
Tools Needed:
5/16 in.
Input5 2013−04 / Ref. 803 766-C / 218 005-A
OM-273025 Page 24
5-10. Connecting Input Power (Continued)
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 10-3 before
proceeding.
!
Installation must meet all National
and Local Codes − have only qualified
persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input
conductors from unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
!
Make input power connections to the
welding power source first.
!
Always
connect
green
or
green/yellow conductor to supply
grounding terminal first, and never to
a line terminal.
See rating label on unit and check input voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 5-3. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Welding Power Source Input Power
Connections
2 Strain Relief (Customer Supplied)
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief. Tighten strain relief.
S Use large strain relief for input conductor
size 8 and larger.
S Use small strain relief with reducing
washers for input conductor size 10.
3 Contactor W1
4 Welding Power Source Grounding
Terminal
5 Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to machine grounding terminal
first.
6 Welding Power Source Line Terminals
7 Input Conductors L1, L2, L3
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Reinstall side panel on welding power
source.
Disconnect
Device
Input
Power
Connections
8 Disconnect Device (switch shown in
the OFF position)
9 Disconnect Device Grounding Terminal
10 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
11 Over-Current Protection
Select type and size of over-current protection using Section 5-9 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
Input5 2013−04
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-273025 Page 25
SECTION 6 − GENERAL OPERATION
6-1. Front Panel
3
5
4
2
6
7
8
9
10
11
12
17
1
13
14
15
16
Ref. 273 528-B
. The welding power source will power up
in the factory setting of Remote MIG the
first time it is turned on. Thereafter the
welding power source will power up in the
process it was in when turned off.
. Weld
1
2
process operation sections describe functionality of the identified items
(See Sections 7-2 thru 9-2).
Remote 14 Receptacle
Remote In Use Indicator
OM-273025 Page 26
3
4
Left Display
Right Display
. The meters display the actual weld output
5
6
7
8
values after arc initiation and remains displayed for approximately three seconds
after the arc is broken.
Adjust Control
Volts Indicator
Inductance Indicator
Amps Indicator
9
10
11
12
13
14
15
16
17
DIG Indicator
Arc Control Stiff Indicator
Arc Control Soft Indicator
Arc Control Button
Mode Switch
Weld Output Terminal (+)
Optional Gas Valve Knockout
Weld Output Terminal (−)
Power Switch
6-2. Mode Switch Settings
Switch Position
WIRE − Gas
WIRE − Gas (1)
Process
GMAW
FCAW
GMAW
FCAW
Output Control
Panel Adjust
Remote 14
Adjust
ArcReach Adjust
Remote 14
Volts
Volts
−−
Electrode Hot
Volts
Volts
Volts
WIRE - No Gas (1)
FCAW-S
Electrode Hot
Volts
Volts
Volts
STICK EXX18 (1)
SMAW
Electrode Hot
Amps
% Panel Amps*
Amps
STICK EXX10 (1)
SMAW
Electrode Hot
Amps
% Panel Amps*
Amps
GOUGE (1)
CAC-A
Electrode Hot
Amps
% Panel Amps*
Amps
Lift-Arc TIG (1)
GTAW
Electrode Hot
Amps
% Panel Amps
Amps
TIG
GTAW
Remote 14
Amps
% Panel Amps
−−
(1) An ArcReach device will override any control connected to remote 14-pin receptacle.
*See Section 9-4 Alternate Configuration Functions
6-3. Associating ArcReach Device To ArcReach Power Source
Quick Setup Guide:
1
2
Make connections between power source and ArcReach device. (See section pertaining to mode being used for typical connection
diagrams).
This power source has the ability to associate with an ArcReach device at power up, or when an ArcReach wire feeder is triggered. The
Mode Switch on this power source must be set to an “OUTPUT ON” mode to associate with another ArcReach device.
3
See instructions in the owner’s manual for the specific ArcReach device to associate the device to this power source.
4
5
During the association process the Remote in Use indicator will blink.
When the association process is complete, the Remote In Use indicator will be lit. Dependent on the capabilities of the ArcReach device; the
mode switch, voltage/amperage adjustment, and Arc Control adjustment may be overridden by the ArcReach device.
Notes
OM-273025 Page 27
SECTION 7 − GTAW OPERATION
7-1. Typical Connection For GTAW Process
5
4
3
2
1
6
7
8
9
252920-B
!
Turn off power before making connections.
1
Foot Control
2
Positive (+) Weld Output Terminal
OM-273025 Page 28
3
Remote 14 Receptacle
6
Gas Out Connection (Optional)
Connect desired remote control to Remote
14 receptacle if required.
7
Negative (−) Weld Output Terminal
4
5
8
TIG Torch
9
Workpiece
Gas In Connection (Optional)
Gas Cylinder
7-2. Lift-Arc TIG Welding Mode - GTAW Lift-Arc - Output ON
3
6
4
10
5
2
9
1
273 528-B
8
“Touch”
1−2
Seconds
7
Do NOT Strike Like A Match!
!
1
2
3
4
5
6
7
8
9
10
Weld terminals are energized at all
times in Lift Arc TIG welding mode.
Mode Switch
Volts Indicator
Left Display
Right Display
Amps Indicator
Adjust Control
Workpiece
Tungsten Electrode
Remote 14 Receptacle
Remote In Use Indicator
Setup
For typical system connections refer to
Section 7-1.
Set Mode Switch to GTAW LIFT-ARC posi-
tion.
ON is shown in the Left Display. Preset amperage is shown in the Right Display with
the Amps Indicator lit.
Normal open-circuit voltage is not present
before the electrode touches the workpiece, instead a low sensing voltage is
present. The sensing voltage allows the
electrode to touch the workpiece without
overheating, sticking, or getting contaminated.
Operation
The Adjust Control is used to set desired
preset amperage.
. If a remote control is connected to the
Remote14 Receptacle and used for
amperage adjustment, the adjustment
will function as a percentage of the pre-
set amperage. The Remote In Use indicator will be lit.
. If an ArcReach device is used for am-
perage adjustment, it will have full
range of the preset amperage. Dependent on the capabilities of the device, it
may have the ability to override parameter adjustments and mode switch setting. The Remote In Use indicator will
be lit. An ArcReach device will override
a remote control connected to the Remote 14 Receptacle.
. For best results, firmly touch the tung-
sten electrode to the workpiece at the
weld start point. Hold electrode to
workpiece for 1-2 seconds, and lift
electrode. An arc will form when the
electrode is lifted. To minimize arc flare
at the end of the weld, pull back the
electrode quickly to extinguish the arc.
OM-273025 Page 29
7-3. TIG Welding Mode - GTAW Process - Remote ON/OFF
2
5
3
7
4
6
1
273 528-B
!
1
2
3
4
5
6
7
Weld terminals are energized
through the remote control in TIG
welding mode.
Mode Switch
Left Display
Right Display
Amps Indicator
Adjust Control
Remote 14 Receptacle
Remote In Use Indicator
Setup
For typical system connections refer to
Section 7-1.
Set Mode Switch to GTAW TIG position.
The preset amperage is shown in the Right
Display with the Amps Indicator lit.
Operation
The Adjust Control is used to set desired
preset amperage.
A remote control is required to turn on the
weld output.
. If a remote control is connected to the
Remote14 Receptacle and used for
amperage adjustment, the adjustment
will function as a percentage of the preset amperage. The Remote In Use indicator will be lit.
. An
ArcReach remote control is not
compatible in this mode.
. For
best results, gently scratch the
tungsten electrode to the work to initiate an arc. To minimize arc flare at the
end of the weld, pull back the electrode
quickly to extinguish the arc.
OM-273025 Page 30
SECTION 8 − GMAW/FCAW OPERATION
8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process
9
1
2
3
8
7
4
6
5
252921-B
!
Turn off power before making
connections.
5
Workpiece
6
Gun
7
Wire Feeder
1
Remote 14-Receptacle
2
Positive (+) Weld Output Terminal
3
Negative (−) Weld Output Terminal
8
Gas Hose
4
Ground Cable to Workpiece
9
Gas Cylinder
Use of shielding gas is dependant on Wire
Type.
. The
connection diagram illustrates
DCEP (reverse polarity) suitable for all
wires except self-shielded FCAW-S.
The majority of self-shielded FCAW-S
wires require DCEN (straight polarity).
OM-273025 Page 31
8-2. MIG Welding Mode - GMAW/FCAW Process - Remote ON/OFF
3
5
4
10
2
7
6
9
8
11
1
273 528-B
!
1
2
3
4
5
6
7
8
9
10
11
Weld terminals are energized
through the remote control in this
mode.
Mode Switch
Volts Indicator
Left Display
Right Display
Adjust Control
Arc Control Indicator For Wire Modes
Arc Control Indicator
Arc Control Button
Arc Control Soft Indicator
Remote In Use Indicator
Remote 14 Receptacle
Setup
For typical system connections refer to
Section 8-1.
OM-273025 Page 32
Set Mode Switch to GMAW/FCAW GAS,
REMOTE ON/OFF position.
The preset voltage is shown in the Left Display with the Volts Indicator lit.
Operation
While the Volts Indicator is lit under the Left
Display, the Adjust Control is used to set
desired preset voltage.
Arc Control
. The preset voltage can be adjusted re-
Rotate Adjust Control to select desired Arc
Control setting from 0 to 25 Soft and 0 to 25
Stiff. Minimum Arc Control setting is Soft
25. Maximum Arc Control setting is Stiff 25.
Mid-range setting of 0 is good for most applications. Use lower Arc Control settings
to stiffen the arc and reduce puddle fluidity.
Use higher Arc Control settings to soften
the arc and increase puddle fluidity.
motely at the wire feeder if the feeder
has a voltage control. This voltage control will override the Adjust Control of
preset voltage on the welding power
source. The Remote In Use indicator
will be lit.
. An
ArcReach remote control is not
compatible in this mode.
Pressing the Arc Control button allows adjustment of Arc Control settings.
Pressing the Arc Control button will cause
the Arc Control Indicator to light. Dependent on the setting: the STIFF or SOFT indicator will light and STIF or SOFT will appear
on the Left Display. 0 to 25 will appear on
the Right Display. If set to 0 neither STIF or
SOFT will appear.
After three seconds of inactivity the Adjust
Control will revert back to adjusting preset
voltage.
8-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW/FCAW-S Process
10
1
9
2
3
8
4
7
5
6
274429-B
!
Turn off power before making connections.
1
2
3
4
5
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
Ground Cable to Workpiece
Workpiece
Voltage Sensing Clamp
6
Gun
7
Gun Trigger Receptacle
8
Wire Feeder
9
Gas Hose
10 Gas Cylinder
Use of shielding gas is dependant on Wire
Type.
. The
connection diagram illustrates
DCEP (reverse polarity) suitable for all
wires except self-shielded FCAW-S.
The majority of self-shielded FCAW-S
wires require DCEN (straight polarity).
OM-273025 Page 33
8-4. V-Sense Feeder Welding Mode - GMAW/FCAW/FCAW-S Output ON
3
5
4
10
2
7
6
9
8
11
1
273 528-B
!
Weld terminals are energized at all
times in these modes.
1
2
3
4
5
6
7
8
9
10
11
Mode Switch
Volts Indicator
Left Display
Right Display
Adjust Control
Arc Control Stiff Indicator
Arc Control Indicator For Wire Modes
Arc Control Button
Arc Control Soft Indicator
Remote In Use Indicator
Remote 14 Receptacle
Setup
For typical system setup connections refer
to Section 8-3.
Set Mode Switch to FCAW-S NO GAS, or
GMAW/FCAW GAS, OUTPUT ON position.
The Left Display toggles between ON and
OM-273025 Page 34
preset arc voltage with the Volts indicator lit.
Operation
While the Volts indicator is lit under the Left
Display, the Adjust Control is used to set
desired preset voltage.
. The Left Display toggling momentarily
pauses while the preset voltage is adjusted.
If a remote control is connected to the Remote 14 Receptacle and used for voltage
adjustment, the adjustment will have full
range of preset voltage. The Remote In Use
indicator will be lit.
. If an ArcReach device is used for volt-
age adjustment, it will have full range of
the preset voltage. Dependent on the
capabilities of the device, it may have
the ability to override parameter adjustments and mode switch setting. The
Remote In Use indicator will be lit. An
ArcReach device will override a re-
mote control connected to the Remote
14 Receptacle.
Pressing the Arc Control button allows adjustment of Arc Control settings.
Arc Control
Pressing the Arc Control button will cause
the Arc Control indicator to light. Dependent on the setting: the STIFF or SOFT indicator will light and STIF or SOFT will appear
on the Left Display. 0 to 25 will appear on
the Right Display. If set to 0 neither STIF or
SOFT will appear.
Rotate Adjust Control to select desired Arc
Control setting from 0 to 25 Soft and 0 to 25
Stiff. Minimum Arc Control setting is Soft
25. Maximum Arc Control setting is Stiff 25.
Mid-range adjustment of 0 is good for most
applications. Use lower Arc Control settings to stiffen the arc and reduce puddle
fluidity. Use higher Arc Control settings to
soften the arc and increase puddle fluidity.
After three seconds of inactivity the Adjust
Control will revert back to adjusting preset
voltage.
SECTION 9 − SMAW/CAC-A OPERATION
9-1. Typical Connection For SMAW And CAC-A Process
5
4
3
1
2
6
7
252926-B
!
Turn off power before making connections.
cutting torch to to positive weld output terminal.
Connect desired remote control to remote
14 receptacle as required.
1
Electrode Holder
(Carbon Arc)
2
3
4
5
6
7
For CAC-A process connect carbon arc
Electrode Holder
Positive (+) Weld Output Terminal
Remote 14 Receptacle
Compressed Air LIne
Negative (−) Weld Output Terminal
Workpiece
OM-273025 Page 35
9-2. Stick Welding Modes - SMAW EXX18/SMAW EXX10/CAC-A Gouge - Output ON
3
6
4
12
2
5
7
9
10
8
11
273 528-B
1
!
Weld terminals are energized at all
times in this mode.
1 Mode Switch
2 Volts Indicator
3 Left Display
4 Right Display
5 Amps Indicator
6 Adjust Control
7 Arc Control Indicator For Stick Modes
8 Arc Control Button
9 Arc Control Stiff Indicator
10 Arc Control Soft Indicator
11 Remote 14 Receptacle
12 Remote In Use Indicator
Setup
For typical system connections refer to
Section 9-1.
Set Mode Switch to SMAW EXX18, SMAW
EXX10, CAC-A Gouge - Output ON position.
ON is shown in the Left Display. Preset amperage is shown in the Right Display with
the Amps Indicator lit.
Operation
While the Amps Indicator is lit under the
Right Display, the Adjust Control is used to
set desired preset amperage.
Pressing the Arc Control button allows adOM-273025 Page 36
justment of Arc Control and Programmable
Hot Start settings.
. If a remote control is connected to the
Rotate Adjust Control to select desired Arc
Control setting from 0 to 25 Soft and 0 to 25
Stiff. Minimum Arc Control setting is Soft 25.
Maximum Arc Control setting is Stiff 25.
Mid-range adjustment of 0 is good for most
applications.
. If an ArcReach device is used for am-
Arc Control allows the arc characteristics,
soft versus stiff, to be changed for specific
applications and electrodes. Lower the Arc
Control setting for smooth running electrodes like E7018 and increase the Arc
Control setting for stiffer, more penetrating
electrodes like E6010.
Remote 14 Receptacle and used for
amperage adjustment, the adjustment
will function as a percentage of the preset amperage. The Remote In Use indicator will be lit.
perage adjustment, it will have full
range of the preset amperage. Dependent on the capabilities of the device, it
may have the ability to override parameter adjustments and mode switch setting. The Remote In Use indicator will
be lit. An ArcReach device will override
a remote control connected to the Remote 14 Receptacle.
. For best results at the end of the weld,
pull back the electrode quickly to extinguish the arc.
. See Section 9-4 for information regard-
ing Alternate Configurations.
Arc Control
Pressing the Arc Control button will cause
the Arc Control Indicator to light. Dependent
on the setting: the STIFF or SOFT indicator
will light and STIF or SOFT will appear on
the Left Display. 0 to 25 will appear on the
Right Display. If set to 0 neither STIF or
SOFT will appear.
After three seconds of inactivity the Adjust
Control will revert back to adjusting preset
amperage.
. While
in Air Carbon Arc (CAC−A)
mode, Arc Control is not adjustable.
Hot Start Time
Press and hold the Arc Control button until
HOT.S appears on the left display. Rotate
Adjust Control to enable Automatic Hot
Start Time (AUTO) or to set Hot Start Time
from Min (0.1 seconds) to Max (5.0 seconds). A separate Hot Start Time may be
set for EXX18 and EXX10 modes.
After three seconds of inactivity the Adjust
Control will revert back to adjusting preset
amperage.
. While
in Air Carbon Arc (CAC−A)
mode, Hot Start Time is not adjustable.
9-3.
Low Open Circuit Voltage (OCV)
Low OCV Operation
The unit is configured at the factory for low open circuit voltage (OCV) operation in OUTPUT ON: Wire, Stick, Lift-Arc TIG modes.
9-4. Alternate Configuration Functions
There are 2 ways that the remote control can be configured to operate on this machine. The configuration of the meters can be changed by placing
the process selection switch into either Stick or Gouge modes and turning the output on and off 3-5 times within a few seconds, this can be done
by triggering a feeder or by activating the output on-off switch on a remote control. The feeder or remote control must be connected to the remote
14 receptacle. The amperage window will briefly display what mode is selected before returning to a preset display.
C1
C2
Configuration 1 is the factory default setting. Stick or
Gouge modes recognize a remote plugged into the remote 14 receptacle, the amperage window will display the
percentage of preset being set from the remote, the panel
will set the maximum amperage. An ArcReach device will
have full range control and override a remote connected
to the remote 14 receptacle.
In either Stick or Gouge modes Configuration 2 changes
the operation of any remote control connected to the remote 14 receptacle. When Configuration 2 is selected either Stick or Gouge modes operate in Panel Only control.
Any remote control connected to the remote 14 receptacle will be ignored and have no effect on the output. When
either Stick or Gouge modes are active, a decimal point
will be displayed in the amperage window. Configuration
2 has no affect on the operation of an ArcReach device.
OM-273025 Page 37
SECTION 10 − MAINTENANCE & TROUBLESHOOTING
10-1. Routine Maintenance
!
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Repair Or
Replace
Cracked
Cables
Replace
Damaged Or
Unreadable
Labels
Replace Cracked
Torch Body
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
Blow Out Inside
10-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 252018-B
OM-273025 Page 38
10-3. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460
Volt Models
4
!
Turn Off welding power
source, and disconnect input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
1
Right Side Panel
Typical Bleeder Resistor
25 to 1000 ohm,
5 watt resistor
To remove panel, remove screws
securing panel to unit.
#16 AWG 1000 volts DC
insulation rating, approx.
3 in. (76 mm) leads
1
2
Relinking Board PC6
3
Voltmeter
Measure the DC voltage across the
screw terminals on PC6 as shown
until voltage drops to near 0 (zero)
volts.
. If the capacitor voltage does
not drop to near zero after several minutes, use a bleeder resistor of between 25 and 1000
ohms, at least 5 watts, #16
AWG 1000 volts DC insulating
rating wire to discharge the capacitor(s) .
2
3
4
Typical Bleeder Resistor
An example of a typical bleeder resistor is shown on this page.
Proceed with job inside unit. Reinstall right side panel when finished.
230 VAC input:
+ lead to lower
terminal, − lead to
upper terminal
2
3
460 VAC input:
+ lead to lower right
terminal, − lead to
upper left terminal
Tools Needed:
5/16 in.
252019-A / 252018-B
OM-273025 Page 39
10-4. Removing Right Side Panel and Measuring Input Capacitor Voltage In 575
Volt Models
4
!
Turn Off welding power
source, and disconnect input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
1
Right Side Panel
Typical Bleeder Resistor
25 to 1000 ohm,
5 watt resistor
To remove panel, remove screws
securing panel to unit.
#16 AWG 1000 volts DC
insulation rating, approx.
3 in. (76 mm) leads
1
2
Balance Board PC6
3
Voltmeter
Measure the DC voltage across the
screw terminals on PC6 as shown
until voltage drops to near 0 (zero)
volts.
. If the capacitor voltage does
not drop to near zero after several minutes, use a bleeder resistor of between 25 and 1000
ohms, at least 5 watts, #16
AWG 1000 volts DC insulating
rating wire to discharge the capacitor(s) .
4
2
Typical Bleeder Resistor
An example of a typical bleeder resistor is shown on this page.
3
Proceed with job inside unit. Reinstall right side panel when finished.
575 VAC input:
+ lead to lower
terminal, − lead to
upper terminal
Tools Needed:
5/16 in.
Ref. 252018-B / 801718 / Ref. 256682-B
OM-273025 Page 40
10-5. Help Displays
HELP
1
HELP
6
. All directions are in reference to the front
of the unit. All circuitry referred to is located inside the unit.
Help 1, 6, 7 Display
HELP
7
Indicates a malfunction in the primary power
circuit. If this display is shown, contact a Factory Authorized Service Agent.
HELP
2
Help 2 Display
HELP
3
Help 3 Display
HELP
HELP
5
8
HELP
24
HELP
25
Indicates a malfunction in the thermal protection circuitry. If this display is shown, contact
a Factory Authorized Service Agent.
Indicates the left side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-7). Operation will
continue when the unit has cooled.
Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-7). Operation will
continue when the unit has cooled.
Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. If this display is
shown, contact a Factory Authorized Service
Agent.
Help 24, 25 Display
Indicates machine has reached Duty Cycle
limit (see Section 4-7). Unit must be left on to
power the fan for cooling. Duty Cycle limit will
automatically reset when unit has cooled.
OM-273025 Page 41
10-6. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-10).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-10).
Check for proper input power connections (see Section 5-10).
No weld output; meter display On.
Input voltage outside acceptable range of variation (see Section 5-9).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-7).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 5-3).
Clean and tighten all weld connections.
Check for correct polarity.
No 24 volts AC output at Remote 14
receptacle.
Reset supplementary protector CB2 (see Section 5-7).
Does not associate to another
ArcReach device.
Check that Mode Switch is set to an “OUTPUT ON” mode.
Check owner’s manual of the other device for correct method to associate the power source to the other
ArcReach device.
Notes
OM-273025 Page 42
Notes
OM-273025 Page 43
SECTION 11 − ELECTRICAL DIAGRAM
Figure 11-1. Circuit Diagram
OM-273025 Page 44
273 334-C
OM-273025 Page 45
SECTION 12 − PARTS LIST
. Hardware is common and
8
not available unless listed.
7
17
16
14
9
18
13
12
11
6
20
15
5
10
21
3
19
22
23
2
24
4
25
1
26
32
31
28
33
34
39
35
40
29
30
36
47
46
37
45
48
38
41
42
49
44
43
50
51
52
Figure 12-1. Parts Assembly
OM-273025 Page 46
27
53
19
54
55
56
67
57
58
69
59
60
71
61
68
62
65
66
63
73
75
64
70
72
77
76
80
81
70
78
83
79
58
82
74
99
87
88
89
90
19
98
86
85
84
95
91
97
96
92
94
93
274572-B
OM-273025 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Parts Assembly
. . . 1 . . . . . . . . . . . . . . 249804 . . Panel, Side Rh W/Nut Insert (230/460V Models) (Includes) . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 178551 . . . . Insulator, Side Small (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . . . . . 252154 . . Panel, Side Rh W/Nut Insert (575V Models) (Includes) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 175256 . . . . Insulator, Side Large (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 276297 . . . . Label, Warning Match Input Pwr To Voltage (EN/FR/SP) . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 237155 . . . . Label, Important Input Power/Relink Connections . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . 249803 . . Panel, Side Lh W/Nut Insert (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 274964 . . . . Label, Warning General Precautionary (EN/FR/SP) . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . +249111 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . 135483 . . Label, Important Remove These Two Handle Screws . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . 249848 . . Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . 275316 . . Label, Warning Falling Equipment (EN/FR/SP) . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . HD1 . . . . 168829 . . Transducer, Current 1000A Module Max Open Loop . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . 183827 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . L7-L10 . . . 268537 . . Core, Toroidal 23.98mm Id X 39.98mm Od X 15.98mm Th . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 196355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 273577 . . Harness, Filter 1 Ohm Resistor Assy 450 ArcReach . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 154408 . . Bushing, Snap−In Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . 179276 . . Bushing, Snap−In Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . . . .
. . . 17 . . . . C13 . . . . 273124 . . Filter Cap Assembly, ArcReach 16uF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . +249527 . . Windtunnel, Lh W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 219844 . . Label, Warning Electric Shock/Exploding Parts−Wdles . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 249618 . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . RT1 . . . . 199798 . . Thermistor, NTC 30K OHM @ 25 Deg C 18.00In2500V . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 201531 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 199840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 232296 . . Resistor/Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 204165 . . Heat Sink, Rect Dual Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . T1 . . . . . 263252 . . XFMR, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 249110 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . 269262 . . Insulator, Base/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 229325 . . Foot, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 176736 . . Screw, Mtg Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . PC3 . . . . 272723 . . Circuit Card Assy, Display XMT 450 CC/CV W/ArcReach . . . . . . . . . . . . .
. . . . . . . . . PLG 18 . . . 131204 . . Housing Plug+Skts (Service Kit) RC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG 23 . . . 131054 . . Housing Plug+Skts (Service Kit) RC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 190512 . . Stand−Off, No 6−32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 231470 . . Nut, Adapter Encoder Shaft Mtg 375−32 To 500−28 . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 274192 . . Holder, LED Front XMT Pcb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . S1 . . . . . 244920 . . Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . 176226 . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 274844 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . 251594 . . Panel, Front W/Nut Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . . 274848 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . 216112 . . Fastener, Panel Receptacle Quick Access . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . 272398 . . Label, Controls XMT 450 CC/CV ArcReach . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . . 231469 . . Nut, 500−28 .69Hex .28H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . . 266591 . . Knob, Encoder 1.250 Dia X 6mm Id Push On W/Spring . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . . 231468 . . Nut, 375−32 .56Hex .21H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . . . . . 245663 . . Knob, Encoder 1.250 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . . . 272656 . . Label, Process XMT 350/450 CC/CV ArcReach . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . . 246919 . . Door, W/Quick Access Ball Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate (Order By Model And Serial Number) . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . . . 175138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-273025 Page 48
1
1
1
1
1
1
1
1
1
2
2
1
1
1
4
4
1
1
2
1
1
3
1
1
4
4
2
1
1
1
1
4
4
1
1
1
2
1
1
1
1
1
1
1
2
1
2
2
2
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Parts Assembly (Continued)
. . . 53 . . . . PC1 . . . . 260544 . . Circuit Card Assy, Control W/Program (230/460V Models) . . . . . . . . . . . .
. . . 53 . . . . PC1 . . . . 260550 . . Circuit Card Assy, Control W/Program (575V Models) . . . . . . . . . . . . . . . .
. . . . . . . . PLG 2, 5,
. . . . . . . . . 7, 8, 10 . . . 131054 . . Housing Plug+Pins (Service Kit) RC2, 5, 7, 8, 10 . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG 3 . . . 130203 . . Housing Plug+Pins (Service Kit) RC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG 4 . . . 115093 . . Housing Plug+Pins (Service Kit) RC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG 6 . . . 115092 . . Housing Plug+Pins (Service Kit) RC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG 9 . . . 115094 . . Housing Plug+Pins (Service Kit) RC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 54 . . . . . . . . . . . . . +249237 . . Panel, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . T2 . . . . . 260655 . . XFMR, Control 230/460 VAC Pri 298Va 60 Hz
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (230/460 Models Without Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . T2 . . . . . 252332 . . XFMR, Control 575 VAC Pri 298Va 60 Hz
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (575 Models Without Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 56 . . . . FM2 . . . . 183918 . . Motor, Fan 24VDC 3000 RPM 43 Cfm W/10 Ohm Resistor . . . . . . . . . . . .
. . . 57 . . . . . . . . . . . . . . 249236 . . Bracket, Mtg Capacitor/PC Board/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . . . 153403 . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . .
. . . 59 . . . . . . . . . . . . . . 255855 . . Bracket, Mtg Ct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 60 . . . . . . . . . . . . . . 177547 . . Bushing, Snap−in Nyl Ct−Mount 1.093 Mtg Hole . . . . . . . . . . . . . . . . . . . . .
. . . 61 . . . . CT1 . . . . 181271 . . XFMR, Current 500 Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 62 . . . . . . . . . . . . . . 251137 . . Cover, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 63 . . . . . . . . . . . . . . 250260 . . Insulator, Capacitor Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 64 . . . . . . . . . . . . . . 256680 . . Kit, Capacitor 230/460 400VAC (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 64 . . . C3-C6 . . . 234104 . . . . Capacitor, Elctlt 2700 Uf 450 VDC Can 2.52 Dia . . . . . . . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . . . 217040 . . . . Nut, Nylon M12 Thread Capacitor Mounting . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 229327 . . . . Screw, M 5− .8X 12 Hex Hd−Phl 8.8 Pld Sems Clr (Not Shown) . . . . . .
. . . 66 . . . . . . . . . . . . . . 251701 . . Adapter, Nut Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 67 . . . . . T2 . . . **260739 . . XFMR, Control Toroidal 230/460 VAC Pri 1456Va 60 Hz
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (230/460 Models With Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 67 . . . . . T2 . . . **256582 . . XFMR, Control 575 VAC Pri 1456Va 60 Hz
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (575 Models With Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 68 . . . . . . . . . . . . **180105 . . Bracket, Mtg XFMR Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 69 . . . . . . . . . . . . **217297 . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . . . .
. . . 70 . . . . . . . . . . . . . . 273211 . . Cable, USB 2.0 A−A Male 1Meter Panel−Mount Ip−67 . . . . . . . . . . . . . . . .
. . . 71 . . . . . . . . . . . . . . 274166 . . Bracket, USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 72 . . . . . . . . . . . . **273375 . . Label, Panel Rear XMT 450 W/Aux USB . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 73 . . . . . . . . . . . . . . 273374 . . Label, Panel Rear CC/CV MPA W/USB . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . . 262913 . . Kit, Strain Relief 1.250 (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . . 255675 . . . . Bushing, Strain Relief .865/1.26 Id X1.250 Mtg Hole . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . . 263092 . . . . Nut, Conduit 1.250−11.5 Npsm Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . . +249119 . . Panel, Rear W/Nut Inserts (Models Without Aux Power) . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . **274444 . . Rear Panel Assy, 450 Aux Power W/USB . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 76 . . . . CB1 . . **083432 . . Supplementary Pro, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . .
. . . 77 . . . . CB2 . . . . 083432 . . Supplementary Pro, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . .
. . . 78 . . . . RC2 . . **604176 . . Rcpt, Str Dx Grd 2P3W 15A 125V *5−15R . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 79 . . . . . . . . . . . . **265204 . . Ring, Aux Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 80 . . . . . . . . . . . . . . 179930 . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 81 . . . . . Z1 . . . . . 270446 . . Stabilizer, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 82 . . . . . . . . . . . . . . 181925 . . Insulator, Stabilizer Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 83 . . . . . L1 . . . . . 180026 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 84 . . . . . . . . . . . . . . 251220 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 85 . . . . FM1 . . . . 175084 . . Fan, Muffin 24VDC 3000 RPM 255 Cfm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . 86 . . . . . . . . . . . . . +249105 . . Windtunnel, Rh W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 87 . . . . . . . . . . . . . . 025248 . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . . .
. . . 88 . . . . . W1 . . . . . 180270 . . Contactor, Def Prp 40A 3P 24VAC Coil W/Boxlug . . . . . . . . . . . . . . . . . . . .
. . . 89 . . . . C1, 2 . . . . 230272 . . Capacitor, Polyp Film .34 UF 1000 VRMS +/−10% . . . . . . . . . . . . . . . . . . .
. . . 90 . . . . . . . . . . . . . . 185992 . . Bus Bar, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 91 . . . . PC2 . . . . 231559 . . Circuit Card Assy, Interconnecting (230/460V Models) . . . . . . . . . . . . . . . .
. . . 91 . . . . PC2 . . . . 252150 . . Circuit Card Assy, Interconnecting (575V Models) . . . . . . . . . . . . . . . . . . . .
1
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OM-273025 Page 49
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Parts Assembly (Continued)
. . . . . . . . . PLG 11 . . . 131056 . . Housing Plug+Skts (Service Kit) RC7, 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG 12 . . . 115093 . . Housing Plug+Skts (Service Kit) RC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG 13 . . . 115091 . . Housing Plug+Skts (Service Kit) RC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 92 . . . . PC6 . . . . 249114 . . Circuit Card Assy, Relink (230/460V Models) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 92 . . . . PC6 . . . . 256426 . . Circuit Card Assy, Balance (575V Models) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 93 . . . . . . . . . . . . . . 218566 . . Gasket, Inductor Mounting E70 Ferrite Core . . . . . . . . . . . . . . . . . . . . . . . .
. . . 94 . . . . L3-L4 . . . . 256646 . . Inductor, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 95 . . . . . . . . . . . . . . 057358 . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole . . . . . . . . . . . . . . . . . . . .
. . . 96 . . . PM1, 2 . . . 276987 . . Kit, Transistor IGBT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 97 . . . . RT2 . . . . 199798 . . Thermistor, Ntc 30K Ohm @ 25 Deg C 18.00In2500V . . . . . . . . . . . . . . . .
. . . 98 . . . . SR1 . . . . 183334 . . Rectifier, Integ Bridge 130. Amp 1600V 3PH . . . . . . . . . . . . . . . . . . . . . . . .
. . . 99 . . . . . . . . . . . . . . 145743 . . Lug, Univ W/Scr 600V 2−14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
**Part of 115V Aux Power Option.
1
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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-273025 Page 50
Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
* MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2016-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2016 Miller Electric Mfg. Co.
2016−01
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