Dimension 650
Issued March 2016 • Index No. DC/19.3
Dimension 650
Heavy Industrial Applications
Fabrication and construction
Heavy manufacturing
MRO — maintenance/repair
Pressure tank/vessel fabrication
Refineries and foundries
Railcar manufacturing
Earth-moving equipment manufacturing
Flux-cored (FCAW)
Submerged arc (SAW)
Stick (SMAW)
Air carbon arc (CAC-A)
cutting and gouging
Rated: 3/8-inch carbons
Multiprocess Welding
Power Source
Input Power 3-phase power
380/460 V, 50/60 Hz
Rated Output 650 A at 44 VDC,
100% duty cycle
Output Range 15–815 A, 10–65 V
Net Weight 158 lb. (71.7 kg)
ArcReach (recommended option)
Remote voltage control without a control cable
Big capabilities in a smaller package.
Developed for harsh environmental conditions and output
requirements that range from power-intensive to precise.
Rugged and durable
inside and out
An unbeatable combination of
durability, output, efficiency and
capability — all in a smaller,
easier-to-handle package. Inside
its tough, corrosion-resistant,
all-aluminum case is big power
for heavy welding jobs and
carbon arc gouging.
Power and precision
In addition to excellent stick and
Lift-Arc™ TIG, the Dimension 650
also has excellent short-arc MIG
characteristics for precise thinmetal welding performance.
Improved weld quality
More portable and
takes up less floor space
ArcReach™ —
remote control without a cord
Power source is warranted for three years, parts and labor.
Original main power rectified parts are warranted for five years.
Miller Electric Mfg. Co.
Equipment Sales US and Canada MillerWelds.com
An ITW Welding Company
1635 West Spencer Street
P.O. Box 1079
Appleton, WI 54912-1079 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
Dimension 650 Advantages
Withstands harsh environments
Rugged and durable
inside and out
All-aluminum construction helps the machine resist
corrosion for long life.
Exclusive protection input inductor protects machine’s
performance and reliability from “dirty” input power.
Wind Tunnel Technology.™ Internal air flow that protects
electrical components and PC boards from dirt, dust,
debris... greatly improving reliability
Fan-On-Demand™ operates only when needed reducing
noise, power consumption, and the amount of airborne
contaminants pulled through the machine.
3.25 inches of
ground clearance
keeps the machine
away from water,
mud and dirt to
protect interior
3.25 in.
Smaller and lighter
Reduced size and weight results in an easier-to-handle
package that exceeds the welding performance of larger,
heavier machines. Weighing in at 158 pounds (71.7 kg), the
Dimension 650 is 3.5 times lighter than the Dimension 652,
making it easier to move around the shop, jobsite, or
shipyard. It also uses 40-percent less floor space.
Previous model
Current model
More portable and
takes up less floor space
40% smaller
Dimension 650 footprint
Dimension 652 footprint
Power efficient
Uses 32% fewer amps
than previous model
High electrical efficiency and excellent power factor
mean that you can get more welding done using less
power. On 460 V, the Dimension 650 draws only 43 amps
at rated load and can operate on a 50-amp service. Four
machines can work at maximum loads simultaneously on
a 200-amp service, drawing less amperage than three
previous models.
Previous model
Dimension 652s
draw 189 amps
Dimension 650s
draw less power –
only 172 amps
Current model
Dimension 650 Advantages
Improved arc performance
Power and precision
Improved weld quality
High-quality performance from power-intensive to
precise. Knowing quality welds begin with a quality arc,
we’ve significantly improved the performance in all welding
processes and made it easy to fine tune the arc to match
your personal preferences and welding style.
Gouging mode provides 800 amps of usable power, a full
650 amps of power at 100-percent duty cycle. Perfect for
heavy gouging with 3/8-inch carbons.
Three wire modes (GMAW/FCAW/SAW) for simplified
setup and optimized arc performance.
• Solid and flux-cored wires with gas offer exceptional
short-arc MIG precision to weld thin metals with less risk
of distortion or burn-through, and premium flux-cored
welding with gas.
• Flux-cored (self-shielded) welding performance is
exceptional, especially with wires commonly found in
infrastructure construction.
• Sub arc mode provides capability to retrofit into
non-digital sub arc applications.
Weld process switch with
Gouge mode, three Wire
modes, Stick mode and
Lift-Arc TIG mode.
Arc control for additional
fine-tuning in Stick or
Solid Wire modes.
Excellent stick and Lift-Arc™ TIG performance.
Arc control is beneficial when welding with stick and solid
wires for easier fine-tuning of tough-to-weld materials and
out-of-position applications.
Dimension 650 Recommended Option
ArcReach accessories
SuitCase feeder
or stick/TIG
For MIG or flux-cored
welding — SuitCase
ArcReach feeders
• Remote voltage control
• Polarity indication
• Auto-Process Select™
power source
Remote control of the power source without a cord. An ArcReach system allows
you to change weld settings from your SuitCase wire feeder or stick/TIG remote,
saving a trip to the power supply. ArcReach technology uses the existing weld cable to
communicate welding control information between the feeder or remote and the power
source. This technology eliminates the need for control cords, and their associated
problems and costs.
For stick or TIG welding —
ArcReach stick/TIG remote
• Remote amperage control
• Arc control for stick
• Polarity indication
• Auto-Process Select™
Dimension 650 Features
Dimension 650 ArcReach
additional features
Remote in use indicator. On
standard Dimension 650 models
the remote in use indicator means
a device (remote control or wire
feeder with a remote control) is
connected to the 14-pin connector.
Digital meters with SunVision™ technology enable welding
parameters to be viewed with greater clarity than analog
meters — at virtually any angle. Meters can be seen clearly
even in direct sunlight.
Meters display
• Process settings for quick and easy setup
• Preset and actual amperage
Remote in use indicator provides
convenient feedback indicating an
ArcReach wire feeder is controlling
the power source. While under
ArcReach control, process and
voltage/amperage adjustments are
locked out, preventing accidental
changes by personnel other than the
welding operator.
NEW! Auto-Bind automatically
establishes an exclusive communication between the power source and
the wire feeder, using the existing
weld cables upon system power up.
LED process indicator. Front panel
process selections are illuminated
with an LED that identifies the active
process. This enables the selected
weld process to be seen at a distance
from the power source.
Fleet compatibility. ArcReachequipped power sources and wire
feeders work with non-ArcReach
equipment; however, the complete
ArcReach benefit is only realized
with the ArcReach system.
• Gouging mode is an optimized
stick position for better gouging
• Three wire modes
(GMAW/FCAW/SAW) for simplified
setup and optimized arc performance
- Solid and flux-cored wires with gas
- Flux-cored (self-shielded)
- Sub arc
• Stick mode for all electrode types
• Lift-Arc™ TIG
Front-panel-mounted power switch
is easy to access when in racks or
manufacturing cells.
Standard 14-pin receptacle with
Auto-Remote Sense™ for simple
connection of remote controls and
wire feeders.
Durable weld cable connections
• Serrated hardware for single-wrench
• Easy double weld cable installation
• Flexible, protective covers prevent
incidental contact
Back panel. 20 amps of 120 V power
to run power tools — like grinders,
chop saws, drills and lights.
Arc control is active in the stick and
solid-wire processes. It allows the
operator to customize arc characteristics
to match preference, electrode and joint
design from a softer arc with more fluid
puddle to a stiffer arc with an more
controllable puddle. The Star setting
is optimized for most applications
and pointing the control at Soft or Stiff
is optimal for most arc preferences.
Control is fully adjustable from 0 to 25
Soft or 0 to 25 Stiff.
Specifications (Subject to change without notice.)
15–815 A in CC mode
10–44 V in CV mode
10–65 V in SAW mode
Rated Output
650 A at 44 VDC,
100% duty cycle
Amps Input at Rated Output, 50/60 Hz
380 V
460 V
Max. OpenCircuit Voltage
Net Weight
H: 28.187 in. (716 mm)
(including lift eye)
W: 16.687 in. (424 mm)
D: 31.625 in. (803 mm)
158 lb.
(71.7 kg)
Wire Feeder Options
Portable Suitcase-Style Feeders
SuitCase® X-TREME™ 8VS and 12VS See literature M/6.42
These voltage-sensing feeders are designed to run off of arc voltage from almost any
welding power source. The 8VS utilizes an 8-inch spool of wire and fits through a
14-inch manhole/manway, while the 12VS adds the capability to utilize 12-inch spools and
is more commonly used in structural steel and fabrication. ArcReach-equipped models
provide remote voltage control of the power source without a cord.
SuitCase® 12RC See literature M/6.45
Standard remote voltage control saves the operator a trip back to the power supply for
welding adjustments. For applications where the feeder is within 100 feet of the power
source and control cords are acceptable.
Bench-Style Feeders
20 Series Feeders See literature M/11.0
22A and 24A — Simple and cost-effective feeders for industrial manufacturing and
70 Series Feeders See literature M/3.0
74S — Standard, simple feeders for most heavy-industrial applications.
74D — Provides increased accuracy and control of the most common weld parameters.
74DX — Provides added features for weld control and programs.
74 MPa Plus — Adds push-pull aluminum capabilities. Optimized for use with XMT® MPa,
Invision™ MPa and Dimension 650 power sources.
Boom-Style Feeders
70 Series Swingarc™ See literature M/13.11
Swingarc single and dual boom-mounted wire feeders bring an extra dimension of flexibility
and efficiency to weld stations dealing with large weldments, or wherever operator mobility
is required.
Aluminum Push-Pull Feeders and Guns
XR™ Controls See literature M/1.7
XR-S Control — Cost-effective push-pull feeder for industrial applications.
XR-D Control — Adds capabilities for higher quality welds.
XR-Aluma-Pro™ Gun See literature M/1.71
Robust professional grade gun has the highest duty-cycle rating in its class.
XR™-Pistol Gun See literature M/1.73
Reliable cost-effective gun for light to medium industrial applications.
XR™-Pistol Pro Gun See literature M/1.74
Exceptional aluminum welding results for heavy industrial applications.
Hard Automation
70 Series Remote Configurations See literature M/3.0
Remote wire feeder control box and wire drive assembly for non-Miller
boom applications.
Sub Arc mode provides capability to retrofit into non-digital sub arc applications.
See literature no. AY/12.0 for list of compatible accessories. Adapter cord, 115 V
for legacy 14-pin accessories is required.
Genuine Miller Accessories
GFCI Panel Mount Kit 301179
For applications that require GFCI protection of
the 115-volt receptacle.
Adapter Cord 301259
115-volt cord for legacy 14-pin accessories.
Required to connect to HDC 1500.
Polarity Control 042871
This dual-function control is designed for use
with dual wire feeders or any application where
electrical isolation and/or polarity reversing of
weld current is required. Both functions can be
used at the same time.
Dimension™ 650 Racks
907687 2-pack rack
907688 4-pack rack (shown above)
Dimension™ 650 ArcReach™ Racks
907702 2-pack rack
907701 4-pack rack
Conveniently houses multiple Dimension 650
power sources for multiple welders. Features
Provision to parallel power sources on
common work connections
Two lifting eyes for transportation
Rugged skids for dragging or pushing
Process Control Selector 042872
Allows you to easily change weld processes
without changing cables — from TIG to MIG or
TIG to stick. Also includes features of polarity
control. Can be used with any constant-current,
constant-voltage or multiprocess CC/CV welding
power source.
Note: Does not accommodate gas cylinders,
use Running Gear Cylinder Rack 300408 when
gas cylinders are required.
HF-251D-1 High-Frequency
Arc Starter/Stabilizer
This portable 250-amp,
60-percent duty cycle unit
adds high frequency to the
welding circuit to help start the arc when using
the TIG (GTAW) process. Operates on 115-volt,
50/60/100 Hz. See literature AY/5.1.
RHC-14 Hand Control*
20-foot (6 m) cord
100-foot (30.5 m) cord
Miniature hand control
for remote current and contactor control.
Dimensions: 4 x 4 x 3.25 inches (102 x 102 x
83 mm). Includes cord and 14-pin plug.
RCC-14 Remote Contactor and Current Control
East/west rotary-motion fingertip control attaches
to TIG torch using two hook-and-loop fasteners.
Allows complete current and contactor control
at operator’s fingertips. Includes 26.5-foot (8 m)
cord and 14-pin plug.
RCCS-14 Remote Contactor and Current
Control 043688
North/south rotary-motion fingertip control
attaches to TIG torch using two hook-and-loop
fasteners. Great for applications that require a
finer amperage control. Includes 26.5-foot (8 m)
cord and 14-pin plug.
Remote Controls and Switches
ArcReach Stick/TIG
Remote 301325
When paired with
an ArcReach power
source, provides
remote control of the
power source without
a cord — saving time
and money. See literature AY/14.5.
Running Gear Cylinder Rack 300408
Small footprint and easily maneuverable, with
cylinder rack low enough that you do not have
to lift bottles.
RFCS-14 Foot Control
Foot current and contactor
control. Includes 20-foot
(6 m) cord and 14-pin plug.
*For additional lengths visit MillerWelds.com/equiptoweld
Industrial MIG 4/0 Kit 300390
Includes Miller flowmeter regulator with 10-foot
(3 m) gas hose, 10-foot (3 m) 4/0 feeder weld
cable with lugs, and 15-foot (4.6 m) work cable
with 600-amp C-clamp.
Dimension™ 650 Running Gear 301307
Large rear wheels and front casters provide
excellent power source mobility on the shop floor.
Easy to install. Handles double as a cable holder.
Wireless Remote Hand
Control 300430
For remote current and
contactor control. Receiver
plugs directly into the
14-pin receptacle of Miller
machine. 300-foot (91.4 m) operating range.
Wireless Remote Foot
Control 300429
For remote current
and contactor control.
Receiver plugs directly
into the 14-pin receptacle of Miller machine.
90-foot (27.4 m) operating range.
RMLS-14 129337
Momentary- and maintained-contact rocker
switch for contactor control. Push forward
for maintained contact and backward for
momentary contact. Includes 26.5-foot (8 m)
cord and 14-pin plug.
Extension Cables for 14-Pin Plugs to
14-Pin Sockets*
242208025 25 ft. (7.6 m)
242208050 50 ft. (15.2 m)
242208080 80 ft. (24.4 m)
Extension cables make a direct connection
between the power source and remote control
or 24 V wire feeder. No messy splicing or
adapting required.
*For additional lengths visit MillerWelds.com/equiptoweld
Genuine Miller Accessories (Continued)
Wire Feeders
Coolant Systems
For more information, see the Coolmate™ Series
literature AY/7.2.
70 Series Wire Feeders
S-74 MPa Plus 951291 single feeder
D-74 MPa Plus 951292 dual feeder
SuitCase® X-TREME™ 8VS 951582
SuitCase® X-TREME™ 12VS 951543
Lightweight, portable wire feeder for a variety
of wires up to .062 inch. Holds up to an 8-inch
(8VS) or 12-inch (12VS) spool of wire. Operates
on open-circuit voltage eliminating the need for
a control/power cord. Includes Bernard™ BTB
Gun 300 A. See literature M/6.42.
Order XR-Aluma-Pro Plus gun and U-grooved drive
rolls separately to match your aluminum needs.
Above models are optimized for Dimension 650
and have push-pull capability.
951196 single feeder
951198 single feeder
951200 single feeder
951203 dual feeder
951204 dual feeder
951206 dual feeder
70 Series feeders feature Posifeed™ wire drive
assembly and handle a variety of wires. Each
includes a 15-foot Bernard™ BTB Gun 400 A
(two for dual feeders) and .035/.045-inch
V-grooved drive rolls. See literature M/3.0.
Welding Intelligence™
SuitCase® X-TREME™ 8VS ArcReach
951588 With Bernard™ S-Gun™
951584 With Bernard™ BTB Gun 300 A
SuitCase® X-TREME™ 12VS ArcReach
951589 With Bernard™ S-Gun™
951581 With Bernard™ BTB Gun 300 A
Portable feeder designed to run off of arc
voltage. When paired with an ArcReach power
sources provides remote control of the power
source without a cord — saving time and
money. See literature M/6.42.
Coolmate™ 3
043007 115 V
043008 230 V
For use with water-cooled torches rated up to
500 amps. Unique paddle-wheel indicator,
external filter and easy-fill spout.
Coolmate™ 4 042288 115 V
For use with water-cooled torches rated up to
600 amps. Tough molded polyethylene case
with carrying handle.
Insight Core™ 14-pin Module 301072
Easy-to-install module brings Insight Core
capabilities to your existing fleet. This simplified,
Internet-based weld data solution collects,
transmits and presents actionable information
to any Web-connected device. Insight Core can
help you increase productivity, improve weld
quality and manage costs.
Coolant 043810
Sold in cases of four one-gallon recyclable
plastic bottles. Miller coolants contain a base of
ethylene glycol and deionized water to protect
against freezing to -37 degrees Fahrenheit
(-38°C) or boiling to 227 degrees Fahrenheit
(108°C). Also contains a compound that resists
algae growth.
Mounting Specifications
Bottom View
4 holes
A. 16.687 in. (424 mm)
B. 14.25 in. (362 mm)
C. 30.25 in. (768 mm)
D. .687 in. (44 mm)
E. 31.625 in. (803 mm)
F. .625 in. (17 mm) dia.
Height: 28.187 in. (716 mm)
Width: 16.687 in. (424 mm)
Depth: 31.625 in. (803 mm)
Ordering Information
Equipment and Options
Stock No.
Dimension 650 Power Source Only
380/460 V, 50/60 Hz
Dimension™ 650 ArcReach™
Power Source Only
380/460 V, 50/60 Hz
Dimension™ 650 Stationary Package
380/460 V, 50/60 Hz. Includes S-74 MPa Plus feeder, Bernard™ BTB Gun 400 A,
.035/.045 drive rolls and industrial MIG 4/0 kit
Dimension™ 650 MIGRunner™ Package
380/460 V, 50/60 Hz. Includes stationary package plus running gear cylinder rack
Dimension 650 Rack
2-pack rack
4-pack rack
Dimension™ 650 ArcReach™ Rack
2-pack rack
4-pack rack
Options and Accessories
Dimension 650 Running Gear
Running Gear Cylinder Rack
GFCI Panel Mount Kit
Adapter Cord
Polarity Control
Process Control Selector
Industrial MIG 4/0 Kit
Includes flowmeter regulator with 10 ft. (3 m) gas hose, 10 ft. (3 m)
4/0 feeder weld cable with lugs, and 15 ft. (4.6 m) work cable with 600-amp C-clamp
HF-251D-1 Starter/Stabilizer
See literature AY/5.1
ArcReach™ Stick/TIG Remote
Point-of-use control for stick or TIG welding and gouging with Dimension 650 ArcReach
Wireless Remote Foot Control
Foot control with wireless 90 ft. (27.4 m) operating range
Wireless Remote Hand Control
Hand control with wireless 300 ft. (91.4 m) operating range
Rocker switch
Fingertip control (east/west)
Fingertip control (north/south)
Hand control with 20 ft. (6 m) cord and 14-pin plug
Hand control with 100 ft. (30.5 m) cord and 14-pin plug
Foot control
115-volt cord for legacy 14-pin accessories. Required to connect to HDC 1500
Remote Controls
Extension Cables
See page 6
Wire Feeders
SuitCase® X-TREME™ 8VS and 12VS
SuitCase X-TREME
8VS and 12VS ArcReach™
See page 7 and literature M/6.42
Point-of-use control for MIG or flux-cored welding with Dimension 650 ArcReach.
See page 7 and literature M/6.42
70 Series
See page 7 and See literature M/3.0
SuitCase® 12RC
See literature M/6.5
See literature M/11.0
See literature M/11.0
See literature M/1.7
XR Push-Pull Guns
See literature M/1.71, M/1.73 and M/1.74
Swingarc™ Boom Feeders
See literature M/13.11
Welding Intelligence™
See page 7
Coolant Systems
See page 7
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