Miller 652 and 812 Owners Manualo278aj_mil

7/30/2019 Miller 652 and 812 Owners Manualo278aj_mil

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652 and 812

Processes

Description

Multiprocess Welding

Arc Welding Power Source

OM-278 163 769A201011

Dimension

Visit our website at

www.MillerWelds.com

File: Multi-Process

CE and non-CE


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Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you dont have time to doit any other way.

Thats why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldnt afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.Weve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.

And if for some reason the unit needs repair,theres a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

Working as hard as you d every power source froMiller is backed by the mhassle-free warranty in thbusiness.

From Miller to You

Mil_Thank 200909


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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Symboles utiliss 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7. . . . .2-4. Proposition californienne 65 Avertissements 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Principales normes de scurit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6. Informations relatives aux CEM 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. General Precautionary Label 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Input Connection Label 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3. Electric Shock And Airflow Label 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Nameplate Safety Symbols 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5. WEEE Label (For Products Sold Within The EU) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6. Symbols And Definitions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Important Information Regarding CE Products (Sold Within The EU) 14. . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Serial Number And Rating Label Location 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Specifications 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Duty Cycle And Overheating 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Volt-Ampere Curves 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Selecting A Location 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Dimensions And Weights 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Tipping 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. 115 VAC Receptacle And Supplementary Protectors 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. Weld Output Terminals 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11. Selecting Cable Sizes 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. Connecting Weld Output Cables 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13. MIG (GMAW) Cable Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14. MIG (GMAW) And Flux Cored (FCAW) Cable Connections 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15. TIG (GTAW) Cable Connections 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16. Remote 14 Receptacle RC8 Information 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17. Connecting Remote Control 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18. Electrical Service Guide 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19. Placing Jumper Links 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20. Connecting Input Power 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls (Non CE Models) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Controls (CE Models) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE & TROUBLESHOOTING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Routine Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Fuse F1 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Short Circuit Shutdown 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 8 PARTS LIST 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTIONS AND ACCESSORIESWARRANTY


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DECLARATION OF CONFORMITYfor European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that theproduct(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

Dimension 812 907361

Council Directives:

2006/95/EC Low Voltage 2004/108/EC Electromagnetic Compatibility

Standards:

IEC 60974-1: 2005 Arc Welding Equipment Welding Power Sources IEC 60974-10: 2007 Arc Welding Equipment Electromagnetic Compatibility Requirements EN 50445 Product family standard to demonstrate compliance of equipment for resistance welding, arc

welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields(0 Hz 300Hz) BS EN 50445:2008.

Signatory:

_____________________________________ ________________________________________

David A. Werba Date of Declaration

MANAGER , PRODUCT DESIGN COMPLIANCE

241431-D

November 29, 2010


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OM-278 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINsom _201003

7

Protect yourself and others from injury read and follow these precautions.

1-1. Symbol UsageDANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICE Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid thehazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded 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 workor ground.

D Do not use AC output in damp areas, if movement is confined, or ifthere 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 follow-

ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!

D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

D Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

D When making input connections, attach proper grounding conductor first double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.D Frequently inspect input power cord for damage or bare wiringreplace cord immediately if damaged bare wiring can kill.

D Turn off all equipment when not in use.D Do not use worn, damaged, undersized, or poorly spliced cables.D Do not drape cables over your body.D If earth grounding of the workpiece is required, ground it direct

with a separate cable.D Do not touch electrode if you are in contact with the work, groun

or another electrode from a different machine.D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will bepresent.

D Use only well-maintained equipment. Repair or replace damagedparts 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 workpiec

or worktable as near the weld as practical.D Insulate work clamp when not connected to workpiece to preven

contact with any metal object.D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.

D Turn Off inverter, disconnect input power, and discharge inpucapacitors according to instructions in Maintenance Sectionbefore touching any parts.

HOT PARTS can burn.D Do not touch hot parts bare handed.D Allow cooling period before working on equip-

ment.D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.


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D Keep your head out of the fumes. Do not breathe the fumes.D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.D If ventilation is poor, wear an approved air-supplied respirator.D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

D Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).

D Wear approved safety glasses with side shields under yourhelmet.

D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistantmaterial (leather, heavy cotton, or wool) and foot protection.

ARC RAYS can burn eyes and skin.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis 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 cancause fire on the hidden side.D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

D Do not weld where the atmosphere may contain flammable dust,gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.

D Do not use welder to thaw frozen pipes.D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavyshirt, 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 sparkglowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,they can throw off slag.

D Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill.D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMcan affect ImplantedMedical Devices.

D Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

D Implanted Medical Device wearers should consult their doctoand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationarsupport or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuitD 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 shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them andassociated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.D Keep protective cap in place over valve except when cylinder is i

use or connected for use.D Use the right equipment, correct procedures, and sufficient num-

ber 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.


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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 isproperly 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 toextend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.

D Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94110) when manu-ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATINGD Allow cooling period; follow rated duty cycle.D Reduce current or reduce duty cycle before

starting to weld again.D Do not block or filter airflow to unit.

FLYING SPARKS can injure.D Wear a face shield to protect eyes and face.D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing properface, hand, and body protection.

D Sparks can cause fires keep flammables away.

STATIC (ESD) can damage PC boards.D Put on grounded wrist strap BEFORE handling

boards or parts.D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.D Keep away from moving parts.D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.D Do not press gun trigger until instructed to do

so.D Do not point gun toward any part of the body,

other people, or any metal when threadingwelding wire.

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 isfinished and before reconnecting input power.

READ INSTRUCTIONS.D Read and follow all labels and the Owners

Manual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

D Use only genuine replacement parts from the manufacturer.D Perform maintenance and service according to the Owners

Manuals, industry standards, and national, state, and localcodes.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

D Have only qualified persons familiar withelectronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

D If notified by the FCC about interference, stop using theequipment at once.

D Have the installation regularly checked and maintained.D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

D Be sure all equipment in the welding area iselectromagnetically compatible.

D To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.D Be sure this welding machine is installed and grounded

according to this manual.D 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.


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SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATIONfre_som_201003

7

Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

DANGER! Indique une situation dangereuse qui si onlvite pas peut donner la mort ou des blessures graves.Les dangers possibles sont montrs par les symbolesjoints ou sont expliqus dans le texte.Indique une situation dangereuse qui si on lvite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrs par les symboles joints ousont expliqus dans le texte.

NOTE Indique des dclarations pas en relation avec des blessures personnelles.

.Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGEDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECCHAUDES. Consulter les symboles et les instructions ci-dessous yaffrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce ma-nuel pour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructionsen matire de scurit indiques ci-dessous ne constituentquun sommaire des instructions de scurit plus compltesfournies dans les normes de scurit numres dans la Sec-tion 2-5. Lire et observer toutes les normes de scurit.

Seul un personnel qualifi est autoris installer, faire fonc-tionner, entretenir et rparer cet appareil.

Pendant le fonctionnement, maintenir distance toutes lespersonnes, notamment les enfants de lappareil.

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr lasortie. Le circuit dalimentation et les circuits inter-nes de la machine sont galement sous tensionlorsque lalimentation est sur Marche. Dans le modede soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalli-ques en contact avec le fil sont sous tensionlectrique. Un quipement install ou mis la terrede manire incorrecte ou impropre constitue undanger.

D Ne pas toucher aux pices lectriques sous tension.D Porter des gants isolants et des vtements de protection secs et

sans trous.D Sisoler de la pice couper et du sol en utilisant des housses ou

des tapis assez grands afin dviter tout contact physique avec lapice couper ou le sol.

D Ne pas se servir de source lectrique courant lectrique dans leszones humides, dans les endroits confins ou l o on risque detomber.

D Se servir dune source lectrique courant lectrique UNIQUE-MENT si le procd de soudage le demande.

D Si lutilisation dune source lectrique courant lectrique savrencessaire, se servir de la fonction de tlcommande si lappareilen est quip.

D Dautres consignes de scurit sont ncessaires dans les condi-tions suivantes : risques lectriques dans un environnementhumide ou si lon porte des vtements mouills ; sur des structuresmtalliques telles que sols, grilles ou chafaudages ; en positioncoince comme assise, genoux ou couche ; ou sil y a un risquelev de contact invitable ou accidentel avec la pice souder oule sol. Dans ces conditions, utiliser les quipements suivants,

dans lordre indiqu : 1) un poste souder DC tension constante( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste

souder AC tension vide rduite. Dans la plupart des situations,lutilisation dun poste souder DC fil tension constante est re-commande. En outre, ne pas travailler seul !

D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouilllalimentationselon la norme OSHA 29 CFR 1910.147 (voir nomes de scurit).

D Installer le poste correctement et le mettre la terre convenable-ment selon les consignes du manuel de loprateur et les normesnationales, provinciales et locales.

D Toujours vrifier la terre du cordon dalimentation. Vrifier sassurer que le fil de terre du cordon dalimentation est bienraccord la borne de terre du sectionneur ou que la fiche ducordon est raccorde une prise correctement mise la terre.

D En effectuant les raccordements dentre, fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions.

D

Les cbles doivent tre exempts dhumidit, dhuile et de graisse;protgezles contre les tincelles et les pices mtalliqueschaudes.

D Vrifier frquemment le cordon dalimentation afin de sassurequil nest pas altr ou nu, le remplacer immdiatement sil lesUn fil nu peut entraner la mort.

D Lquipement doit tre hors tension lorsquil nest pas utilis.D Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

sante ou mal pisss.D Ne pas enrouler les cbles autour du corps.D Si la pice soude doit tre mise la terre, le faire directement

avec un cble distinct.D Ne pas toucher llectrode quand on est en contact avec la pice,

la terre ou une lectrode provenant dune autre machine.D Ne pas toucher des porte lectrodes connects deux machines

en mme temps cause de la prsence dune tension vide dou-ble.D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le

champ les pices endommages. Entretenir lappareil conform-ment ce manuel.

D Porter un harnais de scurit si lon doit travailler au-dessus du solD Sassurer que tous les panneaux et couvercles sont correctement

en place.D Fixer le cble de retour de faon obtenir un bon contact mtal-

mtal avec la pice souder ou la table de travail, le plus prs pos-sible de la soudure.

D Isoler la pince de masse quand pas mis la pice pour viter lecontact avec tout objet mtallique.

D Ne pas raccorder plus dune lectrode ou plus dun cble demasse une mme borne de sortie de soudage.


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Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur UNE FOISlalimentation coupe.

D Arrter les convertisseurs, dbrancher le courant lectrique etdcharger les condensateurs dalimentation selon les instructionsindiques dans la partie Entretien avant de toucher les pices.

LES PICES CHAUDES peuventprovoquer des brlures.

D Ne pas toucher mains nues les partieschaudes.

D Prvoir une priode de refroidissement avant dtravailler lquipement.

D Ne pas toucher aux pices chaudes, utiliser les outils recomman-ds et porter des gants de soudage et des vtements pais pourviter les brlures.

LES FUMES ET LES GAZ peuventtre dangereux.Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

D Eloigner votre tte des fumes. Ne pas respirer les fumes.D lintrieur, ventiler la zone et/ou utiliser une ventilation force au

niveau de larc pour lvacuation des fumes et des gaz desoudage.

D Si la ventilation est mdiocre, porter un respirateur anti-vapeursapprouv.

D Lire et comprendre les spcifications de scurit des matriaux(MSDS) et les instructions du fabricant concernant les mtaux, lesconsommables, les revtements, les nettoyants et les dgrais-seurs.

D Travailler dans un espace ferm seulement sil est bien ventil ouen portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes etdes gaz de soudage peuvent dplacer lair et abaisser le niveaudoxygne provoquant des blessures ou des accidents mortels.Sassurer que lair de respiration ne prsente aucun danger.

D Ne pas souder dans des endroits situs proximit doprationsde dgraissage, de nettoyage ou de pulvrisation. La chaleur etles rayons de larc peuvent ragir en prsence de vapeurs et for-mer des gaz hautement toxiques et irritants.

D Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soitbien ventil, et en portant un respirateur alimentation dair. Lesrevtements et tous les mtaux renfermant ces lments peuventdgager des fumes toxiques en cas de soudage.

LES RAYONS DE LARC peuventprovoquer des brlures dans lesyeux et sur la peau.Le rayonnement de larc du procd de soudaggnre des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brlure

dans les yeux et sur la peau. Des tincelles sont projetes pendant lsoudage.D Porter un casque de soudage approuv muni de verres filtrants

appropri pour protger visage et yeux pour protger votre visageet vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1et Z87.1 numr dans les normes de scurit).

D Porter des lunettes de scurit avec crans latraux mme sousvotre casque.

D Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissementset les tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

D Porter des vtements confectionns avec des matires rsistan-tes et ignifuges (cuir, coton lourd ou laine) et des bottes deprotection.

LE SOUDAGE peut provoquer unincendie ou une explosion.Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent

tre projetes de larc de soudure. La projection dtincelles, despices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avecdes objets mtalliques peut provoquer des tincelles, une explosionun surchauffement ou un incendie. Avant de commencer le soudagevrifier et sassurer que lendroit ne prsente pas de danger.

D Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit les recouvrisoigneusement avec des protections homologus.

D Ne pas souder dans un endroit l o des tincelles peuvent tombersur des substances inflammables.

D Se protger et dautres personnes de la projection dtincelles etde mtal chaud.

D Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

D Surveiller tout dclenchement dincendie et tenir un extincteur proximit.

D Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

D Ne pas effectuer le soudage sur des conteneurs ferms tels quedes rservoirs, tambours, ou conduites, moins quils naient tprpars correctement conformment AWS F4.1 (voir les nor-mes de scurit).

D Ne soudez pas si lair ambiant est charg de particules, gaz, ou va-peurs inflammables (vapeur dessence, par exemple).

D Brancher le cble de masse sur la pice le plus prs possible de lazone de soudage pour viter le transport du courant sur unelongue distance par des chemins inconnus ventuels en provo-quant des risques dlectrocution, dtincelles et dincendie.

D Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

D En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

D Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sansrevers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos po-ches telles quun allumeur au butane ou des allumettes.

D Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

D Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux chaud et avoir de la surveillance et unextincteur proximit.

DES PIECES DE METAL ou DESSALETES peuvent provoquer desblessures dans les yeux.

D Le soudage, lcaillement, le passage de la pice la brosse enfil de fer, et le meulage gnrent des tincelles et des particulesmtalliques volantes. Pendant la priode de refroidissement dessoudures, elles risquent de projeter du laitier.

D Porter des lunettes de scurit avec crans latraux ou un cranfacial.


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LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort.

D Fermer lalimentation du gaz protecteur en casde non-utilisation.

D Veiller toujours bien arer les espaces confi-ns ou se servir dun respirateur dadductiondair homologu.

Les CHAMPS LECTROMAGNTIQUES (CEM)peuvent affecter les implants mdicaux.

D Les porteurs de stimulateurs cardiaqueset autres implants mdicaux doivent rester distance.

D Les porteurs dimplants mdicaux doivent consulterleur mdecin et le fabricant du dispositif avant de sapprocherde la zone o se droule du soudage larc, du soudagepar points, du gougeage, de la dcoupe plasmaou une opration de chauffage par induction.

LE BRUIT peut endommager loue.Le bruit des processus et des quipements peutaffecter loue.

D Porter des protections approuves pour lesoreilles si le niveau sonore est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endom-mage, elle peut exploser. Du fait que les bouteillesde gaz font normalement partie du procd de

soudage, les manipuler avec prcaution.

LES BOUTEILLES peuvent explosersi elles sont endommages.

D Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, des dommages physiques, du laitier, desflammes ouvertes, des tincelles et des arcs.

D

Placer les bouteilles debout en les fixant dans un support station-naire ou dans un porte-bouteilles pour les empcher de tomber oude se renverser.

D Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

D Ne jamais placer une torche de soudage sur une bouteille gaz.D Une lectrode de soudage ne doit jamais entrer en contact avec

une bouteille.D Ne jamais souder une bouteille pressurise risque dexplosion.D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifique ;les maintenir ainsi que les lments associs en bon tat.

D Dtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

D Le couvercle du dtendeur doit toujours tre en place, sauf lorsquela bouteille est utilise ou quelle est relie pour usage ultrieur.

D Utiliser les quipements corrects, les bonnes procdures et suffi-samment de personnes pour soulever et dplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimlquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scu-rit.

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OUDEXPLOSION.

D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables.

D Ne pas installer lappareil proximit de pro-duits inflammables.

D Ne pas surcharger linstallation lectrique sassurer quelalimentationest correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LQUIPEMENT peutprovoquer des blessures.

D Utiliser lanneau de levage uniquement poursoulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

D Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

D En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

D Tenir lquipement (cbles et cordons) distance des vhiculesmobiles lors de toute opration en hauteur.

D Suivre les consignes du Manuel des applications pour lquationde levage NIOSH rvise (Publication N94110) lors du levagemanuelle de pices ou quipements lourds.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.

D Prvoir une priode de refroidissement ; res-pecter le cycle opratoire nominal.

D Rduire le courant ou le facteur de marcheavant de poursuivre le soudage.

D Ne pas obstruer les passages dair du poste.

LES TINCELLES PROJETESpeuvent provoquer des blessures.

D Porter un cran facial pour protger le visage etles yeux.

D Affter llectrode au tungstne uniquement lmeuleuse dote de protecteurs. Cett

manuvre est excuter dans un endroit srlorsque lon porte lquipement homologu dprotection du visage, des mains et du corps.

D Les tincelles risquent de causer un incendie loigner toute sub-stance inflammable.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.

D tablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

D Utiliser des pochettes et des botes antista-tiques pour stocker, dplacer ou expdier descartes de circuits imprimes.


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Les PICES MOBILES peuventcauser des blessures.

D Ne pas sapprocher des organes mobiles.D Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures.

D Ne pas appuyer sur la gchette avant denavoir reu linstruction.

D Ne pas diriger le pistolet vers soi, dautrespersonnes ou toute pice mcanique enengageant le fil de soudage.

Les PICES MOBILES peuventcauser des blessures.

D Sabstenir de toucher des organes mobiles telsque des ventilateurs.

D Maintenir ferms et verrouills les portes,panneaux, recouvrements et dispositifs deprotection.

D Lorsque cela est ncessaire pour des travaux dentretien et dedpannage, faire retirer les portes, panneaux, recouvrementsou dispositifs de protection uniquement par du personnel qua-lifi.

D Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS.D Lire et appliquer les instructions sur les

tiquettes et le Mode demploi avant linstal-lation, lutilisation ou lentretien de lappareil.Lire les informations de scurit au dbut dumanuel et dans chaque section.

D Nutiliser que les pices de rechange recommandes par leconstructeur.

D Effectuer lentretien en respectant les manuels dutilisation, lesnormes industrielles et les codes nationaux, dtat et locaux.

LE RAYONNEMENT HAUTEFRQUENCE (H.F.) risque deprovoquer des interfrences.

D Le rayonnement haute frquence (H.F.) peutprovoquer des interfrences avec les qui-pements de radionavigation et de com-munication, les services de scurit et les ordi-nateurs.

D Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstallation.

D Lutilisateur est tenu de faire corriger rapidement par un lectriciequalifi les interfrences rsultant de linstallation.

D Si le FCC signale des interfrences, arrter immdiatement lap-pareil.

D Effectuer rgulirement le contrle et lentretien de linstallationD Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs une distan-ce correcte et utiliser une terre et un blindage pour rduire lesinterfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.

D Lnergie lectromagntique risque deprovoquer des interfrences pour lquipementlectronique sensible tel que les ordinateurs etlquipement command par ordinateur tel queles robots.

D Veiller ce que tout lquipement de la zone de soudage soitcompatible lectromagntiquement.

D Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

D Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

D Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

D En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation de c-

bles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiquesdont ltat de Californie reconnat quils provoquent des mal-formations congnitales et, dans certains cas, des cancers.(Code de sant et de scurit de Californie, chapitre 25249.5et suivants)

Les batteries, les bornes et autres accessoires contiennentdu plomb et des composs base de plomb, produits chimi-ques dont ltat de Californie reconnat quils provoquent descancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs manipu-lation.

Ce produit contient des produits chimiques, notamment duplomb, dont ltat de Californie reconnat quils provoquent

des cancers, des malformations congnitales ou dautresproblmes de procration. Se laver les mains aprsutilisation.

Pour les moteurs essence :

Les gaz dchappement des moteurs contiennent des pro-duits chimiques dont ltat de Californie reconnat quilsprovoquent des cancers et des malformations congnitalesou autres problmes de procration.

Pour les moteurs diesel :

Les gaz dchappement des moteurs diesel et certains deleurs composants sont reconnus par ltat de Californie com-me provoquant des cancers et des malformationscongnitales ou autres problmes de procration.


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2-5. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, de GlobalEngineering Documents (tlphone : 1-877-413-5184, site internet :www.global.ihs.com).National Electrical Code , NFPA Standard 70, de National Fire Protec-tion Association, Quincy, MA 02269 (tlphone : 800-344-3555, site

Internet : www.nfpa.org et www.sparky.org).Safe Handling of Compressed Gases in Cylinders , CGA Pamphlet P-1,de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-tilly, VA 20151 (tlphone : 703-788-2700, site Internet :www.cganet.com).Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, de Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (tlphone :800-463-6727, site internet : www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, de American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (tlphone : 212-642-490site Internet : www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other Hot Work , NFPA Standard 51B, de National Fire Protection AssociatioP.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-300site Internet : www.nfpa.org).OSHA, Occupational Safety and Health Standards for GeneraIndustry, Title 29, Code of Federal Regulations (CFR), Part 1910Subpart Q, and Part 1926, Subpart J, de U.S. Government PrintingOffice, Superintendent of Documents, P.O. Box 371954, Pittsburgh, P15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureauxrgionauxle tlphone de la rgion 5, Chicago, est 312-353-2220, siteInternet : www.osha.gov).U.S. Consumer Product Safety Commission (CPSC), 4330 East WesHighway, Bethesda, MD 20814 (tlphone : 301-504-7923, site intenet : www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation , TheNational Institute for Occupational Safety and Health (NIOSH), 16Clifton Rd, Atlanta, GA 30333 (tl[hone : 1-800-232-4636, site interwww.cdc.gov/NIOSH).

2-6. Informations relatives aux CEMLe courant lectrique qui traverse tout conducteur gnre des champslectromagntiques (CEM) certains endroits. Le courant de soudagecre un CEM autour du circuit et du matriel de soudage. Les CEMpeuvent crer des interfrences avec certains implants mdicauxcomme des stimulateurs cardiaques. Des mesures de protection pourles porteurs dimplants mdicaux doivent tre prises: par exemple, desrestrictions daccs pour les passants ou une valuation individuelledes risques pour les soudeurs. Tous les soudeurs doivent appliquer lesprocdures suivantes pour minimiser lexposition aux CEM provenantdu circuit de soudage:1. Rassembler les cbles en les torsadant ou en les attachant avec

du ruban adhsif ou avec une housse.2. Ne pas se tenir au milieu des cbles de soudage. Disposer les

cbles dun ct et distance de loprateur.3. Ne pas courber et ne pas entourer les cbles autour de votre

corps.

4. Maintenir la tte et le torse aussi loin que possible du matriel dcircuit de soudage.

5. Connecter la pince sur la pice aussi prs que possible de lasoudure.

6. Ne pas travailler proximit dune source de soudage, nisasseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou ledvidoir.

En ce qui concerne les implants mdicaux :Les porteurs dimplants doivent dabord consulter leur mdecin avade sapprocher des oprations de soudage larc, de soudage parpoints, de gougeage, du coupage plasma ou de chauffage par induc-tion. Si le mdecin approuve, il est recommand de suivre leprocdures prcdentes.


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SECTION 3 DEFINITIONS3-1. General Precautionary Label

Warning! Watch Out! There arepossible hazards as shown by thesymbols.1 Electric shock from welding

electrode or wiring can kill.1.1 Wear dry insulating gloves.

Do not touch electrode withbare hand. Do not wear wet ordamaged gloves.

1.2 Protect yourself from electricshock by insulating yourselffrom work and ground.

1.3 Disconnect input plug orpower before working onmachine.

2 Breathing welding fumes canbe hazardous to your health.

2.1 Keep your head out of thefumes.

2.2 Use forced ventilation or localexhaust to remove the fumes.

2.3 Use ventilating fan to removefumes.3 Welding sparks can cause

explosion or fire.3.1 Keep flammables away from

welding. Do not weld nearflammables.

3.2 Welding sparks can causefires. Have a fire extinguishernearby, and have awatchperson ready to use it.

3.3 Do not weld on drums or anyclosed containers.

4 Arc rays can burn eyes andinjure skin.

4.1 Wear hat and safety glasses.Use ear protection and buttonshirt collar. Use weldinghelmet with correct shade offilter. Wear complete bodyprotection.

5 Become trained and read theinstructions before working onthe machine or welding.

6 Do not remove or paint over(cover) the label.


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3-2. Input Connection Label1 Warning! Watch Out! There

are possible hazards asshown by the symbols.

2 Electric shock from wiring cankill.

3 Disconnect input plug orpower before working onmachine.

4 Read the Owners Manualbefore working on thismachine.

5 Consult rating label for inputpower requirements, andcheck power available at the job site they must match.

6 Read Owners Manual andinside labels for connectionpoints and procedures.

7 Move jumper links as shownon inside label to matchvoltage at job site.

8 Having a loop of extra length,connect grounding conductorfirst.

9 Connect line input conductors

as shown on inside label

double-check all connections, jumper link positions, andinput voltage before applyingpower.

S-179 290

1

4

5

32

? V? A

? V

3

1/96 1 2 3 4

5 6 87 9

3-3. Electric Shock And Airflow Label

S-179 563

1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.

2 Electric shock from wiring andexposed weld terminals cankill.

3 Close door before turning onunit.

1 2 3

1/96

3-4. Nameplate Safety Symbols1 Warning! Watch Out! There

are possible hazards asshown by the symbols.

2 Electric shock from weldingelectrode or wiring can kill.

3 Sparks from arcing electrodecan cause explosion or fire

disconnect cable for processnot in use.4 Read Owners Manual for

connection procedures.5 Electric shock from wiring can

kill.6 Disconnect input power

before working on unit ormaking terminal stripconnections.

Nameplate D-179 389

1

2 3 45 6

1


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3-5. WEEE Label (For Products Sold Within The EU)

Do not discard product (where ap-plicable) with general waste.Reuse or recycle Waste Electricaland Electronic Equipment (WEEE)by disposing at a designated collec-tion facility.Contact your local recycling officeor your local distributor for furtherinformation.

3-6. Symbols And Definitions. Some symbols are found only on CE products.

A Amperes Amperage/VoltageControlPanel Gas Tungsten ArcWelding (GTAW) Shielded Metal ArcWelding (SMAW)Temperature Wire Feeder Arc Force (DIG) Gas Metal ArcWelding (GMAW)

Output Circuit Breaker Remote V VoltsPositive High In-ductance WeldOutput Terminal

Positive Low In-ductance WeldOutput Terminal

Negative WeldOutput Terminal Input

On Off Percent Direct Current

U0 Rated No LoadVoltage (Average) U1 Primary Voltage U2 Conventional LoadVoltage Line ConnectionI1 Primary Current I2 Rated WeldingCurrent X Duty Cycle

Three-PhaseTransformer

Rectifier

IP Degree OfProtection Three-Phase S1 KVA Hz HertzS Suitable For AreasOf IncreasedShock Hazard Protective Earth(Ground)


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SECTION 4 INSTALLATION4-1. Important Information Regarding CE Products (Sold Within The EU)A. Information On Electromagnetic Fields (EMF)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.This equipment is built in accordance with EN 609741 and is intended to be used only in an occupational environment (where the general pubaccess is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the wcircuit may not be a major contributor to the EMF. See the Owners Manuals for all components of the welding circuit for additional EMFinformation.S The EMF assessment on this equipment was conducted at 0.5 meter.

S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.ce-emf 1 2010-10

B. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public lowvoltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due toconducted as well as radiated disturbances.

IEC/TS 6100034 may be used to guide the parties concerned by the installation of arc welding equipment with an input current above 75 Ain a low-voltage network. ce-emc 5 2010-10

4-2. Serial Number And Rating Label LocationThe serial number and rating information for the power source is located on the front or the rear of the machine. Use the rating labels to deinput power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-3. Specifications

Model IPRatingRated

WeldingOutput

Amperage/ Voltage

Range DCMax

OCVDC

Amperes Input at Rated Load Output,50 or 60 Hz, Three-Phase

230 V

380 V

400 V

440 V

460 V

520 V

575 V KVA KW

650 Amp 21M

650 A @ 44Volts DC,

100% DutyCycle

50 815 AIn CC Mode71 (70) VDC

InCC Mode** 1263.8*

771.9*

731.8*

661.6*

631.9*

541.1*

50.41.4*

501.52*

34.80.76*

10 65 V InCV Mode

40 (66) VDCIn

CV Mode** *While idling( ) Indicates specification differences for CE models **Open-circuit voltage is 26 volts DC if unit is equipped with optional low open-circuit voltage.

Notes


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4-4. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.

NOTICE Exceeding duty cyclecan damage unit and void warranty.

100% Duty Cycle

Overheating0

15

A/V

ORReduce Duty CycleMinutes

168 918

Continuous Welding

100 200 300 400 500 600 700 800 900 10000

DC Amperes

D C

V o

l t s

4-5. Volt-Ampere CurvesVolt-ampere curves show mini-mum and maximum voltage andamperage output capabilities ofunit. Curves of other settings fall be-tween curves shown. *High inductance connection.

A. *CC Mode B. CV Mode

168 916-A / 168 917-A

0

10

20

30

40

50

60

70

80

DC Amperes

D C

V o

l t s

100 200 300 400 500 600 700 800 900 100000

10

2030

40

50

60

70

SMAW ARC FORCE

SMAW ARC FORCE

MIN MAX MIN MAX

SMAWGTAW MAX

MED

MIN

GMAWFCAW


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4-6. Selecting A Location1 Lifting Eye2 Lifting ForksUse lifting eye or lifting forks tomove unit.If using lifting forks, extend forksbeyond opposite side of unit.3 Line Disconnect DeviceLocate unit near correct inputpower supply.! Special installation may be

required where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

3

18 in.(460 mm)

18 in.(460 mm)

OR

1

2

Movement

Location And Airflow


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4-7. Dimensions And Weights

A

B C

D

E

F

G H

4 Holes

800 453-A / 801 530Front

Dimensions

A 30 in. (762 mm) Including lift eye

B 23 in. (584 mm)

C 38 in. (965 mm) Including strainrelief

D 35 in. (889 mm)

E 1-1/4 in. (32 mm)

F 21-1/8 in. (537 mm)

G 1-1/8 in. (29 mm)

H 7/16 in. (11 mm) Dia

Weight

545 lb (247 kg)

Notes


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4-8. Tipping! Be careful when placing or

moving unit over unevensurfaces.

4-9. 115 VAC Receptacle And Supplementary Protectors

3

Ref. 800 166-D

! Turn Off power beforeconnecting to receptacle.

1 115 V 15 A AC ReceptacleRC9

Power is shared between RC9 andRemote 14 receptacle RC8 (seeSection4-17).2 Supplementary Protector CB13 Supplementary Protector CB2CB1 protects the 115 volts AC por-tion of RC8 and RC9 from overload.CB2 protects the 24 volts AC por-tion of RC8 and Remote Power On/ Off from overload.Press button to reset protector.

1

2

4-10. Weld Output Terminals

Ref. 800 166-D

! Turn Off power beforeconnecting to weld outputterminals

1 Positive High InductanceTerminal

2 Positive Low InductanceTerminal

3 Negative Weld OutputTerminalSee Sections4-13, 4-14or4-15.

1 2

3


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4-11. Selecting Cable Sizes

! Turn off power be-fore connecting toweld output termi-nals.

! Do not use worn,damaged, under-sized, or poorlyspliced cables.

Weld OutputTerminals

Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***

100 ft (30 m) or Less 150 ft(45 m)200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

WeldingAmperes

10 60%DutyCycle

AWG (mm2 )

60 100%DutyCycle

AWG (mm2 )

10 100% Duty CycleAWG (mm2 )

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2 ea. 2/0(2x70)2 ea. 2/0(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2 ea. 2/0(2x70)2 ea. 3/0(2x95)

2 ea. 3/0(2x95)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2 ea. 2/0(2x70)2 ea. 3/0(2x95)

2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)2 ea. 2/0(2x70)2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

2 ea. 4/0(2x120)

500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0(2x70)2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

3 ea. 3/0(3x95)

3 ea. 3/0(3x95)

600 3/0 (95) 4/0 (120) 2 ea. 2/0(2x70)2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

3 ea. 3/0(3x95)

3 ea. 4/0(3x120)

3 ea. 4/0(3x120)

700 4/0 (120) 2 ea. 2/0(2x70)2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

3 ea. 3/0(3x95)

3 ea. 4/0(3x120)

3 ea. 4/0(3x120)

4 ea. 4/0(4x120)

800 4/0 (120) 2 ea. 2/0(2x70)2 ea. 3/0(2x95)

2 ea. 4/0(2x120)

3 ea. 4/0(3x120)

3 ea. 4/0(3x120)

4 ea. 4/0(4x120)

4 ea. 4/0(4x120)

*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 (Hob

Ref. S-0007-G 200908


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4-12. Connecting Weld Output Cables

803 778-B

! Turn off power before connecting toweld output terminals.

! Failure to properly connect weldcables may cause excessive heatand start a fire, or damage your ma-chine.

1 Weld Output Terminal2 Supplied Weld Output Terminal Nut3 Weld Cable Terminal4 Copper BarRemove supplied nut from weld output ter-minal. Slide weld cable terminal onto weld

output terminal and secure with nut so thatweld cable terminal is tight against copperbar.Do not place anything between weldcable terminal and copper bar. Makesure that the surfaces of the weld cableterminal and copper bar are clean.

Tools Needed:3/4 in. (19 mm)

4

2

3

Do not placeanything between

Correct Installation Incorrect Installation

1

weld cable terminaland copper bar.

4-13. MIG (GMAW) Cable Connections

Polarity: For Electrode Positive (DCEP),connect weld cables as shown. For Electrode Negative (DCEN), typical for Gasless Flux Cored Welding, reverse cableconnections at welding power source.

Gas Flowmeter/ Regulator

Rear OfWire Feeder

+ +

HIGHINDUCTANCE

LOWINDUCTANCE

or

! Turn Off power before making connections.

. For better performance for most GMAW (DCEP and DCEN) applications, it is recommended that weld output connec-tions be made to the Low Inductance weld output terminal.


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4-14. MIG (GMAW) And Flux Cored (FCAW) Cable Connections


Rear OfWire Feeder

+ +

HIGHINDUCTANCE

LOWINDUCTANCE

or

GMAW / FCAW

Rear OfWire Feeder

+ +

LOWINDUCTANCE

FCAW (Gasless)

(Gasless FCAW)

(Gasless FCAW)


. For better performance for most GMAW and (gas shielded)FCAW (DCEP) applications, it is recommended that weld output connections be made to the Low Inductance weld output terminal. Make connections as shown.


. For better performance for most Gasless Flux Cored FCAW (DCEN) applications, it is recommended that weld output connections be made to the Low Inductance weld output ter-

minal. Make connections as shown.


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4-15. TIG (GTAW) Cable Connections

+ +


HIGHINDUCTANCE

Optional HF Unit! Turn Off power before making connections.

. For better performance for most GTAW applications, it is recommended that electrode negative (DCEN) weld output

connections be made to the high Inductance weld output terminal. Make connections as shown.

4-16. Remote 14 Receptacle RC8 InformationSocket Information

24 VOLTS AC A 24 volts AC. Protected by supplementary protector CB2.B Contact closure to A completes 24 volts AC contactor control circuit.

REMOTE OUTPUT CONTROLC Command reference; 0 to +10 volts DC (CC), +10 volts DC (CV).D Remote control circuit common.E 0 to +10 volts DC input command signal from remote control.F Current feedback; 1 volt per 100 amperes.

H Voltage feedback; 1 volt per 10 arc volts.

115 VOLTS ACI 115 volts, 15 amperes, 60 Hz AC. Protected by supplementary protector CB1J Contact closure to I completes 115 volts AC contactor control circuit.

GNDK G

Chassis common.Circuit common for 24 and 115 volts AC circuits.

REMOTE POWER ON/OFF *

To remote On/Off switch. *

REMOTE VOLTAGE SENSING * Voltage sensing signal from Negative () weld output terminal. * Voltage sensing signal from Positive (+) weld output terminal.

* Not Used


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4-17. Connecting Remote Control

Ref. 800 166-D

! Turn off power before con-necting a remote control.

1 Remote 14 Receptacle RC8Connect remote control to RC8.

OR OR

A JB K I

C L N HD M G

E F

1

4-18. Electrical Service GuideFailure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

60 Hz Models 50 Hz ModelsInput Voltage (V) 230 460 575 380 400 440 520Input Amperes (A) At Rated Output 126 63 50.4 77 73 66 54Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses2 150 70 60 90 90 80 60

Normal Operating Fuses 3 200 90 80 125 110 100 80Min Input Conductor Size In AWG4 1 6 6 4 4 4 6Max Recommended Input Conductor Length In Feet (Me-ters)

208(64)

328(100)

513(156)

335(102)

371(113)

449(137)

419(128)

Min Grounding Conductor Size In AWG4 6 8 8 6 6 8 8

Reference: 2008 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

above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NE

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requ


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4-19. Placing Jumper Links

Ref. 800 103-A

! Disconnect and lockout/tag-out input power beforeinstalling or moving jumperlinks.

Check input voltage available atsite.1 Jumper Link LabelCheck label only one is on unit.2 Jumper LinksMove jumper links to match inputvoltage.Close and secure access door, orgo on to Section4-20.

Tools Needed:

2

1

Do not overtighten jumper link nuts.

3/8 in.3/8 in.

230 VOLTS

Ref. S-174 973-B

575 VOLTS460 VOLTS

380 VOLTS 400 VOLTS 440 VOLTS

Ref. S-174 975-B

220 VOLTS

(FACTORY OPTION)

380 VOLTS 520 VOLTS

177 159-A


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4-20. Connecting Input Power

800 103-C / Ref. 801 116-A

3/8 in.3/8 in.

Tools Needed:

! Installation must meet all Nationaland Local Codes have only quali-fied persons make this installation.

! Disconnect and lockout/tagout inputpower before connecting input con-ductors from unit.

! Make input power connections to thewelding power source first.

! Always connect green or green/yel-low conductor to supply groundingterminal first, and never to a line ter-minal.

See rating label on unit and check input volt-age available at site.1 Input Power Conductors (Customer

Supplied Cord)Select size and length of conductors usingSection4-18. Conductors must comply withnational, state, and local electrical codes. Ifapplicable, use lugs of proper amperagecapacity and correct hole size.Welding Power Source Input Power Con-nections

2 Strain ReliefRoute conductors (cord) through strain reliefand tighten screws.3 Machine Grounding Terminal4 Green Or Green/Yellow Grounding

Conductor5 Reed Switch (Ground Current Sensor)

(Optional)Connect green or green/yellow groundingconductor to welding power source ground-ing terminal first. If unit is equipped with op-tional ground current sensor, route ground-ing conductor through reed switch two timesand connect to grounding terminal.6 Welding Power Source Line Terminals

7 Input Conductors L1 (U), L2 (V) AndL3 (W)Connect input conductors L1 (U), L2 (V) andL3 (W) to welding power source line termi-nals.Close and secure access door on weldingpower source.Disconnect Device Input Power Connec-tions8 Disconnect Device (switch shown in

OFF position)9 Disconnect Device (Supply)

Grounding TerminalConnect green or green/yellow groundingconductor to disconnect device groundingterminal first.10 Disconnect Device Line TerminalsConnect input conductors L1 (U), L2 (V) AndL3 (W) to disconnect device line terminals.11 Over-Current ProtectionSelect type and size of over-current protec-tion using Section4-18(fused disconnectswitch shown).Close and secure door on line disconnectdevice. Remove lockout/tagout device, andplace switch in the On position.

IMPORTANT

GND/

3

PE Earth Ground

Input Contactor

L1 (U)L2 (V)L3 (W)

= GND/PE Earth Ground

8

5

4

2

11

6

3

7

4

9

4

10

1

=

7

3


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SECTION 5 OPERATION5-1. Controls (Non CE Models)

41 2 3

7856

Ref. 184 939

1 Arc Force (Dig) ControlControl increases SMAW short-circuitamperage which allows the operator to usea very short arc length without sticking theelectrode.Set control at 0 for normal welding amperageand GTAW applications. Turn clockwise toincrease short-circuit amperage.2 Process Selector Switch GMAW Mode: For use with flux Cored(FCAW) or submerged arc (SAW) applica-

tions. SMAW (Hot Start On) Mode: Hot Start is

energized for Stick (SMAW). When HotStart is energized, higher short circuit am-perage aids in arc starting. NOTE: use thePositive (+) High Inductance weld outputterminal (see Section4-10).

SMAW (Hot Start Off) Mode: For use withTIG (GTAW), scratch start only, or sub-merged arc (SAW) applications. NOTE:for GTAW, use the Positive (+) High Induc-

tance weld output terminal (see Section4-11).

3 Amperage/Voltage Adjustment ControlWhen Process Selector switch is in theSMAW/GTAW position, turn control clock-wise to increase amperage. Read amperagefrom outer scale of control. When ProcessSelector switch is in the GMAW position, turncontrol clockwise to increase voltage. Volt-

meter value changes as control knob isturned. Control can be adjusted whilewelding.4 Digital MetersWith Process Selector switch in the SMAW/ GTAW position, digital meters will read 0(zero) with contactor off. Digital meters willdisplay actual output voltage and amperagewith contactor on.

With Process Selector switch in the GMAWposition, voltmeter displays preset voltagewith contactor off. Voltmeter and ammeter

display actual output voltage and amperagewith contactor on.5 Power Switch With Indicator Light6 High Temperature Shutdown Light7 Remote Amperage/Voltage Control

SwitchFor front panel control, place switch in Panelposition. For remote control, place switch inRemote position, and connect remote de-

vice (see Section4-17).8 Output Switch (Contactor)For front panel control of output, place switchin Panel position. For remote control of out-put, place switch in Remote position, andconnect remote device (seeSection4-17).! Weld output studs are energized only

when Output switch is in On position,or while welding.

! Turn Off power before connecting re-mote device.


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5-2. Controls (CE Models)

4

Ref. 184 936

1 23

7856

1 Arc Force (Dig) ControlControl increases SMAW short-circuitamperage which allows the operator to usea very short arc length without sticking theelectrode.Set control at 0 for normal welding amperageand GTAW applications. Turn clockwise toincrease short-circuit amperage.2 Process Selector Switch GMAW Mode: For use with flux Cored

(FCAW) or submerged arc (SAW) applica-tions.

SMAW (Hot Start On) Mode: Hot Start isenergized for Stick (SMAW). When HotStart is energized, higher short circuit am-perage aids in arc starting. NOTE: use thePositive (+) High Inductance weld outputterminal (see Section4-10).

SMAW (Hot Start Off) Mode: For use withTIG (GTAW), scratch start only, or sub-merged arc (SAW) applications. NOTE:

for GTAW, use the Positive (+) High Induc-tance weld output terminal (see Section4-11).

3 Amperage/Voltage Adjustment ControlWhen Process Selector switch is in theSMAW/GTAW position, turn control clock-wise to increase amperage. Read amperagefrom outer scale of control. When ProcessSelector switch is in the GMAW position, turncontrol clockwise to increase voltage. Volt-meter value changes as control knob isturned. Control can be adjusted whilewelding.4 Digital MetersWith Process Selector switch in the SMAW/ GTAW position, digital meters will read 0(zero) with contactor off. Digital meters willdisplay actual output voltage and amperagewith contactor on.With Process Selector switch in the GMAWposition, voltmeter displays preset voltagewith contactor off. Voltmeter and ammeter

display actual output voltage and amperagewith contactor on.5 Power Switch With Indicator Light6 High Temperature Shutdown Light7 Remote Amperage/Voltage Control

SwitchFor front panel control, place switch in Panelposition. For remote control, place switch inRemote position, and connect remote de-vice (see Section4-17).8 Output Switch (Contactor)For front panel control of output, place switchin Panel position. For remote control of out-put, place switch in Remote position, andconnect remote device (see Section4-17).! Weld output studs are energized only

when Output switch is in On position,or while welding.

! Turn Off power before connecting re-mote device.


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SECTION 6 MAINTENANCE & TROUBLESHOOTING6-1. Routine Maintenance

! Disconnect power before maintaining.

3 Months

Replaceunreadablelabels.

Clean andtighten weldterminals.

Repair orreplacecracked weldcable.

6 Months

Blow out or vacuum inside.During heavy service, clean monthly.

OR

6-2. Fuse F1

Ref. 800 101-C

! Disconnect and lockout/tag-out input power beforechecking or changing fuse.

1 Fuse F1 (See Parts List ForRating)

Fuse F1 protects control transform-er from overload. If F1 opens, weldoutput and fan motor stops. Re-place F1.Close and secure access door.

1

Tools Needed:3/8 in.

6-3. Short Circuit Shutdown

When contact tip is shorted and sticks to workpiece, the unit output falls to a safe operating level. To resume operelease gun trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damTurn On unit to continue operation.


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6-4. Troubleshooting

Trouble Remedy

No weld output; unit completelyinoperative; pilot light PL1 off.

Place line disconnect device in On position (see Section4-20).

Check for open line fuse(s), and replace if open (see Section4-20).

Check for proper input power connections (see Section4-20).Check for proper jumper link position (see Section4-19).Check fuse F1, and replace if necessary (see Section6-2).

No weld output; power switch pilot lighton.

Unit overheated. Allow unit to cool with fan On (see Section4-4).

If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remotcontrol (see Sections4-16and4-17). If remote is not being used, place switch in On position (seeSection5-1).Check, repair, or replace remote control.

No weld output; power switch pilot lighton; fan off.

Check for proper input power connections (see Section4-20).Check for open line fuse(s), and replace if open, or reset circuit breaker (see Section4-20).Turn power switch off then back on. If no output condition remains, have Factory Authorized Servagent check SCRs.

Limited weld output and lowopen-circuit voltage.

Check position of Remote Amperage/Voltage Control switch (see Section5-1).

Check for open line fuse(s), and replace if open (see Section4-20).Check for proper input power connections (see Section4-20).Check for proper jumper link position (see Section4-19).Clean and tighten all weld output connections.

Unit provides only maximum orminimum weld output.

Have Factory Authorized Service Agent check control board PC1 and hall device HD1.

Check position of Remote Amperage/Voltage Control switch (see Section5-1).Not able to obtain minimum output inCC mode.

Use high inductance weld output terminal when in CC mode to obtain minimum output (see Section4-10).

Erratic or improper weld output. Use proper size and type of weld cable (see Section4-11).Clean and tighten all weld connections.Check wire feeder installation according to Owners Manual.Check position of Process selector switch (see Section5-1).Have Factory Authorized Service Agent check control board PC1 and hall device HD1.

No 115 volts AC output at duplexreceptacle, or Remote 14 receptacle.

Reset supplementary protector CB1 (see Section4-9).

No 24 volts AC output at Remote 14receptacle.

Reset supplementary protector CB2 (see Section4-9).

Fan not operating. Note: fan only runswhen cooling is necessary.

Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.Wandering arc; poor control of arcdirection.

Reduce gas flow rate.

Select proper size tungsten.Properly prepare tungsten.

Tungsten electrode oxidizing and notremaining bright after conclusion ofweld.

Shield weld zone from drafts.

Increase postflow time.Check and tighten all gas fittings.Properly prepare tungsten.Check for water in torch, and repair torch if necessary. See torch Owners Manual.

Digital meter not working properly. Have Factory Authorized Service Agent check control board PC1 and connections, and repnecessary.


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OM-278 Page 30

SECTION 7 ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram


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OM-278 Page 31

218 514-


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OM-278 Page 32

SECTION 8 PARTS LIST

800 703-G

Figure 8-1. Main Assembly (652 Model Illustrated)

. Hardware is common and not available unless listed.

1

2 2

23

4

5

3 0

6 7

3 1

1 8

1 9

1 7

1 6

1 4

1 5

2 0 2

1

1 2 2

3

4

1 1

1 0

2 3

2 4

2 7

2 8

2 9

8

9

1 2

1 3


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OM-278 Page 33

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 8-1. Main Assembly (652 Model Illustrated)

Quantity

1 +179 432 PANEL, side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 179 431 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 164 700 BAFFLE, air 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 162 816 CHANNEL, upright 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 162 820 BAR, mtg lift eye 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 162 830 LIFT EYE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604 536 SCREW, .312-18 x 1.750hexhd gr 5 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 177 279 GASKET, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 173 605 BRACKET, mtg LEM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 HD1 168 829 TRANSDUCER, current 1000A module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG14 115 094 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 164 717 BUS BAR, stab jumper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Z1 180 068 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 C21-23 163 906 CAPACITOR, 50 and 60Hz 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 T2 159 042 TRANSFORMER, control 50VA 24V 230/460/575 (60Hz). . . . . . . . . . . . . . . . . . . . . . . . . . .13 T2 159 043 TRANSFORMER, control 50VA 24V