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OM-250068S 2016−10
Processes
Multiprocess Welding
Description
File: MULTIPROCESS
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.
Mil_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is D Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
D If AC output is required, use remote output control if present on
unit. D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
D Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
semiautomatic 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 welder HOT PARTS can burn.
is recommended. And, do not work alone!
D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to D Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
D Properly install, ground, and operate this equipment according to D To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.
OM-250068 Page 1
D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.
OM-250068 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
OM-250068 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
OM-250068 Page 7
D N’utiliser que les pièces de rechange recommandées par le
constructeur. LE SOUDAGE À L’ARC risque de
D Effectuer l’installation, l’entretien et toute intervention selon les provoquer des interférences.
manuels d’utilisateurs, les normes nationales, provinciales et de D L’énergie électromagnétique risque de
l’industrie, ainsi que les codes municipaux. provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
LE RAYONNEMENT HAUTE l’équipement commandé par ordinateur tel que
FRÉQUENCE (H.F.) risque de les robots.
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut D Veiller à ce que tout l’équipement de la zone de soudage soit com-
provoquer des interférences avec les équi- patible électromagnétiquement.
pements de radio−navigation et de communication, les services D Pour réduire la possibilité d’interférence, maintenir les câbles de
de sécurité et les ordinateurs. soudage aussi courts que possible, les grouper, et les poser aussi
D Demander seulement à des personnes qualifiées familiarisées avec bas que possible (ex. par terre).
des équipements électroniques de faire fonctionner l’installation. D Veiller à souder à une distance de 100 mètres de tout équipement
D L’utilisateur est tenu de faire corriger rapidement par un électricien électronique sensible.
qualifié les interférences résultant de l’installation. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
D Si le FCC signale des interférences, arrêter immédiatement l’appareil. conformément à ce mode d’emploi.
D Effectuer régulièrement le contrôle et l’entretien de l’installation. D En cas d’interférences après avoir pris les mesures précédentes,
D Maintenir soigneusement fermés les portes et les panneaux des il incombe à l’utilisateur de prendre des mesures supplémentaires
sources de haute fréquence, maintenir les éclateurs à une distan- telles que le déplacement du poste, l’utilisation de câbles blindés,
ce correcte et utiliser une terre et un blindage pour réduire les l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
interférences éventuelles. de travail.
Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
Safe29 2012−05
Safe30 2012−05
Notes
OM-250068 Page 9
3-2. Miscellaneous Symbols And Definitions
A Amperage
Gas Metal Arc
Welding (GMAW)
I1eff
Maximum Effec-
tive Supply Cur-
rent
Alternating
Current (AC)
Voltage Sensing
V Voltage Panel
Feeder
On Setup
U2 Conventional
Load Voltage
Voltage Input
Protective Earth
I2 Rated Welding
Current
Output
(Ground) Off
Single Phase
Direct Current
Line Connection (DC)
Increase
Three Phase
Constant Current
Static Frequency
Converter-
Transformer- Flux Cored Arc Suitable For Weld-
Rectifier Welding (FCAW) ing In An Environ-
S ment With In-
X Duty Cycle
Circuit Breaker
creased Risk Of
Electric Shock
Negative
U1 Primary Voltage
Arc Control
Inductance IP Degree Of
Protection
Lift-Arc Trigger
Foot Control Hold Operation
(GTAW)
OM-250068 Page 10
SECTION 4 − SPECIFICATIONS
LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input pow-
er fluctuation.
Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which
reduces contaminants and improves reliability in harsh welding environments.
Fan-On-Demandt cooling system operates only when needed, reducing noise, energy use and the amount of con-
taminants pulled through the machine.
Thermal Overload Protection automatically shuts down the unit, only when necessary to prevent damage to internal
components if the duty cycle is exceeded or air flow and cooling are restricted (see Section 4-7).
Auto Remote Sense enables the unit to automatically sense the connection of a remote control. Operation of the
remote control is dependent on the Mode Switch Setting (see Section 6-2).
Lift-Arct TIG starts provide a contamination free weld without the use of high frequency in the Lift-Arc TIG Welding
Mode (see Section 7-3).
Synergic Pulsed MIG Operation allows single knob control of the arc. As wirefeed speed is increased or decreased,
the pulse parameters increase or decrease matching the power output to the wire speed (see Section 6-3).
DIG control allows the arc characteristics, soft versus stiff, to be changed for specific applications and electrodes in
CC and Stick Welding Modes (see Sections 9-2 and 9-3).
Programmable Hot Start allows the start amperage and time to be changed for CC and Stick Welding Modes (see
Sections 9-2 and 9-3).
Inductance influences the arc stiffness, bead width and appearance, and puddle fluidity in MIG and V-Sense Feeder
Welding Modes (see Sections 8-2 and 8-8).
SharpArct optimizes the size and shape of the arc cone, bead width and appearance, and puddle fluidity in Pulsed
MIG Welding Mode (see Section 8-4).
. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Maximum Amperes Input At Rated
Amperage Open- Load Output 60 Hz, KVA KW
Input Rated Welding Voltage
Range Circuit Three-Phase
Power Output Range
Voltage
DC 230 V 460 V 230/460 230/460
Three 450 A @ 38 Volts DC, 51.0 27.6 22.0 18.9
15 − 600 10 − 38 90
Phase 100% Duty Cycle (0.33*) (0.21*) (0.16*) (0.11*)
*While idling with fan on
OM-250068 Page 11
4-5. Dimensions and Weight
Weight
14.5 in.
F (368 mm)
109 lb (49.4 kg)
Without 115 VAC
E
122 lb (55.3 kg) G
With 115 VAC A
B 250027-C
B. Temperature Specifications
Notes
OM-250068 Page 12
4-7. Duty Cycle and Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 450 Amperes 60% Duty Cycle At 580 Amperes
Overheating
0 A/V
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 − SA-181 560 / 250 541-A
Notes
OM-250068 Page 13
SECTION 5 − INSTALLATION
Movement
2 ! Do not move or operate unit
where it could tip.
OR 3
loc_med 2015-04
Notes
OM-250068 Page 14
5-2. Selecting Input Voltage (230/460 Volt Models Only)
! Turn Off welding power
source, disconnect input
power, and check voltage
on input capacitors accord-
ing to Section 10-3 before
. Be sure to reinstall all four screws proceeding.
securing relinking board in place. Check input voltage available at
site.
1 Voltage Selection View
Window
Check voltage selected in unit.
Changing selection is only neces-
sary if selected value does not
match available input voltage.
1 2 Relinking Board PC6
3 Mounting Screws
4 Receptacle RC8 (Connection
For 230 VAC Input Power)
5 Receptacle RC7 (Connection
For 460 VAC Input Power)
Move relinking board as needed
and connect plug PLG4 (in unit) to
RC8 or RC7 according to input
power voltage.
2 3 4
Tools Needed:
5/16 in.
250026-D / 250030-A
OM-250068 Page 15
5-3. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding 10 − 100% Duty Cycle
Duty Cycle Duty Cycle
Amperes AWG (mm2)
AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02
1 2
OM-250068 Page 16
5-5. Connecting Weld Output Cables
4
1
Do not place
anything between
weld cable terminal
and copper bar.
Tools Needed: 3
! Turn off power before connecting to 1 Weld Output Terminal output terminal and secure with nut so that
weld output terminals. 2 Supplied Weld Output Terminal Nut weld cable terminal is tight against copper
3 Weld Cable Terminal bar. Do not place anything between weld
! Failure to properly connect weld cable terminal and copper bar. Make
cables may cause excessive heat 4 Copper Bar
sure that the surfaces of the weld cable
and start a fire, or damage your ma- Remove supplied nut from weld output ter- terminal and copper bar are clean.
chine. minal. Slide weld cable terminal onto weld
OM-250068 Page 17
5-7. (Optional) 115 Volts AC Duplex Receptacle And Supplementary Protectors
1 (Optional) 115 V 10 Amp AC
Receptacle
2 Supplementary Protector CB1
3 Supplementary Protector CB2
CB1 protects duplex receptacle.
1 2 3 CB2 protects 24 volts AC portion of
Remote 14 receptacle from
overload.
Press button to reset supplement-
ary protector.
250028-C
Notes
OM-250068 Page 18
5-8. Optional Gas Valve Operation And Shielding Gas Connection
Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cylinder
2 Regulator/Flowmeter
Install so face is vertical.
3 Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Obtain and install gas
4 hose.
4 Gas In Fitting
5 Gas Out Fitting
GAS IN
The Gas In and Gas Out fittings
2 have 5/8-18 right-hand threads.
Obtain proper size, type, and length
hose and make connections as fol-
lows:
Connect hose from shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect hose coupler to torch.
Connect one end of gas hose to
hose coupler. Connect remaining
end of gas hose to Gas Out fitting.
Operation
The gas solenoid controls gas flow
during the TIG process as follows:
Remote TIG
Gas flow starts with remote contac-
tor on.
3 1
Gas flow stops at end of post−flow
if current was detected, or with re-
mote contactor off if no current was
detected.
Lift−Arc TIG
Gas flow starts when tungsten
touches work (touch sensed).
Gas flow stops at end of post−flow.
Scratch Start TIG
Gas flow starts when current is de-
tected.
Gas flow stops at end of post−flow.
Post−flow time is factory set to 5
seconds per 100 amps of weld cur-
rent. The minimum post−flow time
is 5 seconds. The maximum post−
flow is 20 seconds (post flow set-
tings are not adjustable by the end
5 user).
GAS OUT
Ref. 250029-C
OM-250068 Page 19
5-9. Electrical Service Guide Elec Serv 2014−01
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
60 Hz Three Phase
Input Voltage (V) 230 460
Input Amperes (A) At Rated Output 51 27.6
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 60 30
Normal Operating 3 80 40
Min Input Conductor Size In AWG 4 6 10
159 271
Max Recommended Input Conductor Length In Feet (Meters)
(48) (83)
Min Grounding Conductor Size In AWG 4 8 10
Notes
OM-250068 Page 20
Notes
OM-250068 Page 21
5-10. Connecting Input Power
= GND/PE
Earth Ground
9
11
L1 L2 L3
6
3 L1
5 L2 7
L3
10
1
1
2
5
4
Tools Needed:
5/16 in.
OM-250068 Page 22
5-10. Connecting Input Power (Continued)
! Turn Off welding power source, and Supplied Cord) Connect input conductors L1, L2, and L3 to
check voltage on input capacitors Select size and length of conductors using welding power source line terminals.
according to Section 10-3 before Section 5-3. Conductors must comply with Reinstall side panel on welding power
proceeding. national, state, and local electrical codes. If source.
applicable, use lugs of proper amperage
! Installation must meet all National
capacity and correct hole size.
Disconnect Device Input Power
and Local Codes − have only qualified Connections
persons make this installation. Welding Power Source Input Power 8 Disconnect Device (switch shown in
Connections the OFF position)
! Disconnect and lockout/tagout input
power before connecting input 2 Strain Relief Kit Supplied With Machine 9 Disconnect Device Grounding Terminal
conductors from unit. Follow estab- Install strain relief of proper size for unit and 10 Disconnect Device Line Terminals
lished procedures regarding the in- input conductors. Route conductors (cord)
stallation and removal of lockout/ through strain relief. Tighten strain relief. Connect green or green/yellow grounding
tagout devices. conductor to disconnect device grounding
3 Contactor W1 terminal first.
! Make input power connections to the 4 Welding Power Source Grounding Connect input conductors L1, L2, and L3 to
welding power source first. Terminal disconnect device line terminals.
! Always connect green or 5 Green Or Green/Yellow Grounding 11 Over-Current Protection
green/yellow conductor to supply Conductor
Select type and size of over-current protec-
grounding terminal first, and never to Connect green or green/yellow grounding tion using Section 5-9 (fused disconnect
a line terminal. conductor to machine grounding terminal switch shown).
See rating label on unit and check input volt- first.
Close and secure door on disconnect device.
age available at site. 6 Welding Power Source Line Terminals Remove lockout/tagout device, and place
1 Input Power Conductors (Customer 7 Input Conductors L1, L2, L3 switch in the On position.
Input5 2013−04
Notes
OM-250068 Page 23
SECTION 6 − GENERAL OPERATION
3 4 5
6 7 8 9 10
11
12
13
14
15
1
17 16
19 18
. Weld process operation sections de- played for approximately three seconds
after the arc is broken.
12 Power Switch
scribe functionality of the identified items. 13 Remote PC Interface
5 Adjust Control 14 Setup Button
1 Remote 14 Receptacle
6 Volts Indicator
2 Output ON Indicator Light 15 Gas Type Indicator
7 Arc Length Indicator
3 Left Display 16 Optional Gas Valve Knockout
8 Amps Indicator
4 Right Display 9 Setup Indicator 17 Mode Switch
. The meters display the actual weld output 10 Wire Type Indicator 18 Weld Output Terminal (−)
values after arc initiation and remains dis- 11 Arc Control Indicator 19 Weld Output Terminal (+)
OM-250068 Page 24
6-2. Mode Switch Settings
Pulsed MIG GMAW-P Remote 14 Arc Length (0−100)* Arc Length (0−100)*
SMAW
CC Remote 14 Amps % Panel Amps
CAC-A
SMAW
Stick Electrode Hot Amps % Panel Amps*
CAC-A
*See Configuration Option Menu (see Section 6-3) For adjustment alternatives.
Notes
OM-250068 Page 25
6-3. Configuration Option Menu
3 4 5
SET -UP
6
7
2
1
246 917-B
OM-250068 Page 26
6-3 Configuration Option Menu (Continued)
V.SEN MIG This option enables MIG (V.SEN MIG) or Pulsed MIG (V.SEN
PULS) when the Mode Switch is in the VSENSE FEEDER
position. See Section 8-2 for MIG operation or Section 8-4 for
Pulsed MIG operation.
PULS AUTO This option sets the PULSED MIG control as manual (PULS
MAN) or Auto (PULS AUTO) operation. When set to manual
operation, the arc length setting on power source and wire
speed setting on wirefeeder need to be adjusted independently
to achieve the desired arc length. When set to Auto operation,
once arc length is determined it is not necessary to change the
arc length value with changes in wirefeed speed.
XMT 450 MPa and synergic feeders allow single knob control
of the arc. As wirefeed speed is increased or decreased, the
pulse parameters increase or decrease matching the power
output to the wire speed.
PULS ARC.L This option allows adjusting the Pulsed MIG process in units
of Arc Length (PULS ARC.L) or preset voltage (PULS VOLT).
WFS MPM:
WFS is displayed in meters per minute
Diameter is displayed in millimeters
VRD OFF This option enables (ON) or disables (OFF) low open circuit
voltage (OCV) operation in Stick and Scratch Start TIG modes.
See Section 9-4 for Low OCV Operation. When enabled, VRD
ON is momentarily displayed after the power-on front panel
LED test.
PANL RMT When the Mode Switch is set to SCRATCH START TIG, LIFT−
ARC TIG, or STICK, the remote command behavior is confi-
gurable. SCRATCH START TIG and LIFT−ARC TIG default to
panel and remote (PANL RMT) amperage adjustment but can
be configured for panel only (PANL ONLY) adjustment. The
default amperage adjustment for STICK is panel only (PANL
ONLY) but can also be configured for panel and remote (PANL
RMT) adjustment. All other Mode Switch positions are non−
configurable and allow both panel and remote (PANL −RMT)
adjustment.
OM-250068 Page 27
6-3 Configuration Option Menu (Continued)
Revision Information
6
7
8
9 250032-C
OM-250068 Page 28
7-2. Scratch Start TIG Welding Mode - GTAW Process
3 4 6
84. 5 85
2 5
246 917-B
4 Right Display
Display with the Volts Indicator lit. Preset
amperage is shown in the Right Display
. For best results, gently scratch the
tungsten electrode to the work to initi-
5 Amps Indicator with the Amps Indicator lit.
ate an arc. To minimize arc flare at the
end of the weld, pull back the electrode
6 Adjust Control
quickly to extinguish the arc.
OM-250068 Page 29
7-3. Lift-Arc TIG Welding Mode - GTAW Process
3 4 6
1 3. 5 85
2 5
246 917-B
1−2
“Touch” Seconds
8
7
OM-250068 Page 30
7-4. TIG Welding Mode - GTAW Process
2 3 5
85
4
246 917-B
OM-250068 Page 31
SECTION 8 − GMAW/GMAW-P/FCAW OPERATION
9
1
250033-C
! Turn off power before making 5 Workpiece Use of shielding gas is dependant on Wire
connections. Type.
6 Gun
1 Remote 14-Receptacle
7 Wire Feeder
. The connection diagram illustrates
2 Positive (+) Weld Output Terminal DCEP (reverse polarity) suitable for all
8 Gas Hose wires except self-shielded FCAW. The
3 Negative (−) Weld Output Terminal majority of self-shielded FCAW wires
4 Ground Cable to Workpiece 9 Gas Cylinder require DCEN (straight polarity).
OM-250068 Page 32
Notes
OM-250068 Page 33
8-2. MIG Welding Mode - GMAW/FCAW Process
3 4 5
25. 0
2 6
7
8
9
246 917-B
! Weld terminals are energized . The preset voltage can be adjusted re- Press the Setup Button to confirm the
selection. The unit will acknowledge a
through the remote control in MIG motely at the wire feeder if the feeder
welding mode. change of wire and gas information by dis-
has a voltage control. This voltage con-
trol will override the Adjust Control of playing PROG LOAD momentarily.
1 Mode Switch
preset voltage on the welding power Arc Control (Inductance)
2 Volts Indicator source.
3 Left Display Press the Setup Button repeatedly until the
Pressing the Setup Button allows adjust- Arc Control indicator is lit. INDU appears on
4 Right Display ment of Arc Control, Wire Type, Gas Type the Left Display, and the corresponding in-
5 Adjust Control and preset voltage. ductance setting appears on the Right Dis-
6 Wire Type Indicator . For best results, select the appropriate play.
7 Arc Control Indicator Wire and Gas Type to match the actual Rotate Adjust Control to select desired in-
wire and gas being used. Refer to the ductance setting from 0 to 100. Use lower
8 Setup Button MIG − Wire and Gas Selection Table inductance settings to stiffen the arc and re-
9 Gas Type Indicator for available wires and gases (see duce puddle fluidity. Use higher inductance
Section 8-3). settings to soften the arc and increase
Setup
Selecting a Wire and Gas puddle fluidity.
For typical system connections refer to
Section 8-1. Press the Setup Button repeatedly until the Refer to the MIG − Wire and Gas Selection
Wire Type indicator is lit. The active Wire Table (see Section 8-3) for suggested in-
Rotate Mode Switch to MIG position as Type will appear in the Left and Right Dis- ductance setting for the specific wire and
shown. play. gas being used.
The preset voltage is shown in the Left Dis- Rotate Adjust Control to select desired Press the Setup Button to return to adjust-
play with the Volts Indicator lit. wire. ment of preset voltage.
Operation Press the Setup Button again so the Gas
Type indicator is lit. The active Gas Type
. Each Wire and Gas Type combination
While the Volts Indicator is lit under the Left has independent preset voltage and in-
will appear in the Left and Right Display.
Display, the Adjust Control is used to set ductance settings. These settings are
desired preset voltage. Rotate Adjust Control to select desired gas. preserved when the unit is turned off.
OM-250068 Page 34
8-3. MIG - Wire and Gas Selection Table
*For self-shielded FCAW wires use the ARGN CO2 gas selection and set inductance to less than 10.
**Wire diameter in inches (mm). Refer to section 6-3 to change displayed units.
Notes
OM-250068 Page 35
8-4. Pulsed MIG Welding Mode - GMAW-P Process
3 4 6
25. 0
2 5 7
8
9
10
246 917-B
1
! Weld terminals are energized Pulsed MIG − Wire and Gas Selection Arc Length - Pulsed MIG Manual Control
through the remote control in Table for available wires and gases (see Section 6-3)
Pulsed MIG welding mode. (see Section 8-5).
Arc length corresponds to the level of ener-
1 Mode Switch Selecting a Wire and Gas gy needed to burn off the welding electrode.
2 Volts Indicator As wire feed speed increases, a higher arc
Press the Setup Button repeatedly until the length setting is required to burn off the
3 Left Display Wire Type indicator is lit. The active Wire additional wire. The arc length setting ap-
Type will appear in the Left and Right Dis- pears in the Left Display when the Arc
4 Right Display
play. Length Indicator is lit. Arc length can be ad-
5 Arc Length Indicator
Rotate Adjust Control to select desired justed from 0 to 100.
6 Adjust Control
wire. After the welding output terminals are ener-
7 Wire Type Indicator
Press the Setup Button again so the Gas gized, but prior to arc initiation, the unit dis-
8 Arc Control Indicator Type indicator is lit. The active Gas Type plays the letter “R” and a reference wire
9 Setup Button will appear in the Left and Right Display. speed (IPM) on the Right Display. The ref-
erence wire speed can be used as a start-
10 Gas Type Indicator Rotate Adjust Control to select desired gas. ing point for the wire speed setting at the
Setup feeder. The wire speed and arc length set-
Press the Setup Button again to confirm the
For typical system connections refer to selection. The unit will acknowledge a ting can then be further adjusted to achieve
Section 8-1. change of wire and gas information by dis- the desired arc length.
playing PROG LOAD momentarily. The Configuration Option Menu (see Sec-
Rotate Mode Switch to PULSED MIG posi-
tion as shown. Arc Control (SharpArc) tion 6-1) can be used to change the arc
length setting (0 to 100) to average arc volt-
The arc length setting is shown in the Left Press the Setup Button repeatedly until the age. Average arc voltage can be used as an
Display with the Arc Length Indicator lit. Arc Control indicator is lit. SHRP appears alternative method to set the Pulsed MIG
Operation on the Left Display, and the corresponding welding arc with the same parameters
SharpArc setting appears on the Right Dis- (voltage and wire speed) as a conventional
While the Arc Length Indicator is lit under play. MIG arc. Lower voltage settings corre-
the Left Display, the Adjust Control is used spond to tighter arc lengths while higher
to set desired arc length setting. Rotate Adjust Control to select desired
voltage settings correspond to longer arc
SharpArc setting from 0 to 50, default is 25.
. The arc length can be adjusted remote- Adjusting the SharpArc setting changes the
lengths. If the voltage mode is selected, the
average voltage preset will be displayed on
ly at the wire feeder if the feeder has a welding arc cone. Lower settings widen the
the Left Display with the Volts Indicator lit.
voltage control. This voltage control arc cone, increases puddle fluidity and flat-
will override the Adjust Control on the tens the weld bead appearance. Arc Length - Pulsed MIG Auto Control
welding power source. (see Section 6-3)
Higher settings narrow the arc cone, re-
Pressing the Setup Button allows adjust- duces puddle fluidity and crowns the weld In Auto operation the arc length setting is
ment of Arc Control, Wire Type, Gas Type bead appearance. 0-100. The programs have been developed
and Arc Length. at 50 arc length setting. Increasing or de-
. Each Wire and Gas Type combination creasing the arc length setting from 50 will
. For best results, select the appropriate has independent Arc Length and Shar- change the arc length. It is not necessary to
Wire and Gas Type to match the actual pArc settings. These settings are pre- change the arc length value when changing
wire and gas being used. Refer to served when the unit is turned off. wire feed speed settings.
OM-250068 Page 36
8-5. Pulsed MIG - Wire and Gas Selection Table
. Other normal gas mixtures can be used by adjusting arc length and sharp arc. Use the program closest to your gas mixture and wire type and
size.
Notes
OM-250068 Page 37
8-6. Remote Process Select
This power source can be used with wire
feeders that support Remote Process Se-
lect. This feature allows the operator to
switch the active welding process between
MIG and Pulsed MIG at the wire feeder. To
determine if the welding system is Remote
Process Select capable, connect the wire
feeder to the power source and review the
power source display variations shown be-
low.
50
Remote Process Select Not Detected
When the power source Right Display is
blank, a wire feeder with Remote Process
Select is not detected. Set the active weld
process at the power source.
Power Source Display − Wire Feeder with
25.0 MIG
Remote Process Select Detected
When the power source Right Display is
MIG, a wire feeder with Remote Process Se-
lect is detected and set for MIG operation.
The active weld process can only be
changed at the wire feeder.
Power Source Display − Wire Feeder with
50 PULS
Remote Process Select Detected and Set
for Pulsed MIG
When the power source Right Display is
PULS, a Remote Process Select wire feeder
is detected and is set for Pulsed MIG opera-
tion. The active weld process can only be
changed at the wire feeder.
Using a Dual Wire Feeder with Remote
Process Select
When using a dual wire feeder with Remote
Process Select, different weld programs for
the left and right side can be selected. The
power source MIG and Pulsed MIG pro-
grams for the left side of wire feeder are se-
lected with the left side of the wire feeder act-
ive. The power source MIG and Pulsed MIG
programs for the right side are selected with
the right side of the wire feeder active. When
the right side of the wire feeder is active, the
power source Right Display will show a
decimal point in the lower right hand corner
as shown.
Power Source Display − Dual Wire Feed-
25.0 MIG.
er with Right Side Active and Set for MIG
OM-250068 Page 38
8-7. Typical Connection For Voltage-Sensing Feeder GMAW/GMAW-P/FCAW Process
! Turn off power before mak-
ing connections.
1 Positive (+) Weld Output
Terminal
2 Negative (−) Weld Output
Terminal
3 Ground Cable to Workpiece
4 Workpiece
5 Voltage Sensing Clamp
6 Gun
7 Gun Trigger Receptacle
8 Wire Feeder
10 9 Gas Hose
10 Gas Cylinder
Use of shielding gas is dependant
on Wire Type.
1
. The connection diagram illus-
trates DCEP (reverse polarity)
suitable for all wires except
self-shielded FCAW. The ma-
9 jority of self-shielded FCAW
wires require DCEN (straight
polarity).
8
3
5
6
250034-C
OM-250068 Page 39
8-8. V-Sense Feeder Welding Mode - GMAW/FCAW Process
3 4 5
2 5.0
2 6
7
8
9
246 917-B
! Weld terminals are energized at all Operation Rotate Adjust Control to select desired gas.
times in V-Sense Feeder welding While the Volts Indicator is lit under the Left
mode. Press the Setup Button again to confirm the
Display, the Adjust Control is used to set
selection. The unit will acknowledge a
1 Mode Switch desired preset voltage.
change of wire and gas information by dis-
2 Volts Indicator . The Left Display toggling momentarily playing PROG LOAD momentarily.
3 Left Display pauses while the preset voltage is ad-
Arc Control (Inductance)
justed.
4 Right Display
Pressing the Setup Button allows adjust- Press the Setup Button repeatedly until the
5 Adjust Control
ment of Arc Control, Wire Type, Gas Type Arc Control indicator is lit. INDU appears on
6 Wire Type Indicator and preset voltage. the Left Display, and the corresponding in-
ductance setting appears on the Right Dis-
7 Arc Control Indicator
. For best results, select the appropriate play.
8 Setup Button Wire and Gas Type to match the actual
9 Gas Type Indicator wire and gas being used. Rotate Adjust Control to select desired in-
ductance setting from 0 to 100. Use lower
Setup Refer to MIG − Wire and Gas Selection
inductance settings to stiffen the arc and re-
Table for available wires and gases (see
For typical system setup connections refer Section 8-3). duce puddle fluidity. Use higher inductance
to Section 8-7. settings to soften the arc and increase
Selecting a Wire and Gas puddle fluidity.
Rotate Mode Switch to V-SENSE FEEDER
Press the Setup Button repeatedly until the
position as shown. Refer to the MIG − Wire and Gas Selection
Wire Type indicator is lit. The active Wire
Table (see Section 8-3) for suggested in-
The Left Display toggles between open cir- Type will appear in the Left and Right Dis-
ductance setting for the specific wire and
cuit voltage and preset voltage with the play.
gas being used.
Volts Indicator lit. Rotate Adjust Control to select desired
wire. . Each Wire and Gas Type combination
Press the Setup Button again so the Gas has independent preset voltage and in-
Type indicator is lit. The active Gas Type ductance settings. These settings are
will appear in the Left and Right Display. preserved when the unit is turned off.
OM-250068 Page 40
8-9. V-Sense Feeder Welding Mode - GMAW-P Process
3 4 6
2 5.0 R200
2 5 7
8
9
10
246 917-B
1
! Weld terminals are energized at all ment of Arc Control, Wire Type, Gas Type Higher settings narrow the arc cone, re-
times in V-Sense Feeder welding and Arc Length. duces puddle fluidity and crowns the weld
bead appearance.
mode.
. For best results, select the appropriate
1 Mode Switch Wire and Gas Type to match the actual . Each Wire and Gas Type combination
2 Volts Indicator wire and gas being used. has independent Arc Length and Shar-
3 Left Display Refer to Pulsed MIG − Wire and Gas Selec- pArc settings. These settings are pre-
tion Table for available wires and gases served when the unit is turned off.
4 Right Display
(see Section 8-5). Arc Length
5 Arc Length Indicator
Selecting a Wire and Gas Arc length corresponds to the level of ener-
6 Adjust Control
Press the Setup Button repeatedly until the gy needed to burn off the welding electrode.
7 Wire Type Indicator As wire feed speed increases, a higher arc
Wire Type indicator is lit. The active Wire
8 Arc Control Indicator Type will appear in the Left and Right Dis- length setting is required to burn off the
9 Setup Button play. additional wire. The arc length setting ap-
pears in the Left Display when the Arc
10 Gas Type Indicator Rotate Adjust Control to select desired
Length Indicator is lit. Arc length can be ad-
wire. justed from 0 to 100.
Setup
Press the Setup Button again so the Gas
For typical system setup connections refer Prior to arc initiation, the unit displays the
Type indicator is lit. The active Gas Type
to Section 8-7. letter “R” and a reference wire speed (IPM)
will appear in the Left and Right Display.
on the Right Display. The reference wire
Rotate Mode Switch to V-SENSE FEEDER Rotate Adjust Control to select desired gas. speed can be used as a starting point for
position as shown. the wire speed setting at the feeder. The
Press the Setup Button again to confirm the
The Left Display toggles between open cir- selection. The unit will acknowledge a wire speed and arc length can then be fur-
cuit voltage and the arc length setting. The change of wire and gas information by dis- ther adjusted to achieve the desired arc
open circuit voltage is shown while the playing PROG LOAD momentarily. length.
Volts Indicator is lit, and the arc length set- The Configuration Option Menu (see Sec-
ting is shown while the Arc Length Indicator Arc Control (SharpArc)
tion 6-3) can be used to change the Arc
is lit. Press the Setup Button repeatedly until the Length setting from 0 to 100 to average arc
Arc Control indicator is lit. SHRP appears voltage. Average arc voltage can be used
Operation
on the Left Display, and the corresponding as an alternative method to set the Pulsed
While the Arc Length Indicator is lit under SharpArc setting appears on the Right Dis- MIG welding arc with the same parameters
the Left Display, the Adjust Control is used play. (voltage and wire speed) as a conventional
to set desired arc length setting. Rotate Adjust Control to select desired MIG arc. Lower voltage settings corre-
. The Left Display toggling momentarily SharpArc setting from 0 to 50, default is 25.
Adjusting the SharpArc setting changes the
spond to tighter arc lengths while higher
voltage settings correspond to longer arc
pauses while the arc length setting is
welding arc cone. Lower settings widen the lengths. If the voltage mode is selected, the
adjusted.
arc cone, increases puddle fluidity and flat- average preset voltage will be displayed on
Pressing the Setup Button allows adjust- tens the weld bead appearance. the Left Display with the Volts Indicator lit.
OM-250068 Page 41
SECTION 9 − SMAW/CAC-A OPERATION
4
3
2
1
250035-C
OM-250068 Page 42
9-2. CC Welding Mode - SMAW/CAC-A Process
2 3 5
85
4
6
246 917-B
! Weld terminals are energized . If the remote control has an amperage Programmable Hot Start
through the remote control in CC adjustment, the adjustment will func-
welding mode. tion as a percentage of the preset am- Press the Setup button repeatedly until
1 Mode Switch perage. HOT.S appears on the left display. HOT.S
Pressing the Setup Button allows adjust- adjusts the Hot Start Amperage to Adaptive
2 Left Display Hot Start (AUTO) or from Min (1) to Max
ment of Arc Control, Hot Start Current, and
3 Right Display (50). Adaptive Hot Start (AUTO) automatic-
Hot Start Time.
4 Amps Indicator ally chooses a default amperage. The Min
5 Adjust Control
. For best results at the end of the weld, (1) setting results in no hot start amperage.
pull back the electrode quickly to extin- Higher numbers result in higher start am-
6 Arc Control Indicator guish the arc. perage.
7 Setup Button Arc Control (Dig)
Setup Press the Setup Button so the Arc Control Press the Setup button again so HOT.T ap-
indicator is lit. DIG appears on the Left Dis- pears on the left display. HOT.T adjusts the
For typical system connections refer to Hot Start Time to Adaptive Hot Start
Section 9-1. play, and the corresponding dig setting ap-
pears on the Right Display. (AUTO) or from Min (1) to Max (50). Adapt-
Rotate Mode Switch to CC position as ive Hot Start (AUTO) automatically
Rotate Adjust Control to select desired dig
shown. chooses a default time. The Min (1) setting
setting from 0 to 100.
results in no hot start time. Higher numbers
The preset amperage is shown in the Right Dig control allows the arc characteristics, result in longer start time.
Display with the Amps Indicator lit. soft versus stiff, to be changed for specific
Operation applications and electrodes. Lower the dig
Press the Setup button to return to adjust-
setting for smooth running electrodes like
While the Amps Indicator is lit under the ment of preset amperage.
E7018 and increase the dig setting for stiff-
Right Display, the Adjust Control is used to er, more penetrating electrodes like E6010.
set desired preset amperage.
Press the Setup Button repeatedly until the . Use this mode for Air Carbon Arc
A remote control is required to turn on the Arc Control light goes out to return to ad- (CAC−A) cutting and gouging. For best
weld output. justment of preset amperage. results, adjust dig setting to maximum.
OM-250068 Page 43
9-3. Stick Welding Mode - SMAW/CAC-A Process
3 4 6
84. 5 85
2 5
7
246 917-B
! Weld terminals are energized at all Right Display, the Adjust Control is used to Programmable Hot Start
times in Stick welding mode. set desired preset amperage.
Pressing the Setup Button allows adjust- Press the Setup button repeatedly until
1 Mode Switch HOT.S appears on the left display. HOT.S
ment of Arc Control, Hot Start Current, and
2 Volts Indicator Hot Start Time. adjusts the Hot Start Amperage to Adaptive
3 Left Display Hot Start (AUTO) or from Min (1) to Max
4 Right Display
. For best results at the end of the weld, (50). Adaptive Hot Start (AUTO) automatic-
pull back the electrode quickly to extin- ally chooses a default amperage. The Min
5 Amps Indicator guish the arc. (1) setting results in no hot start amperage.
Higher numbers result in higher start am-
6 Adjust Control Arc Control (Dig) perage.
7 Arc Control Indicator Press the Setup Button so the Arc Control
8 Setup Button indicator is lit. DIG appears on the Left Dis- Press the Setup button again so HOT.T ap-
play, and the corresponding dig setting ap- pears on the left display. HOT.T adjusts the
Setup Hot Start Time to Adaptive Hot Start
pears on the Right Display.
For typical system connections refer to (AUTO) or from Min (1) to Max (50). Adapt-
Rotate Adjust Control to select desired dig ive Hot Start (AUTO) automatically
Section 9-1. setting from 0 to 100. chooses a default time. The Min (1) setting
Rotate Mode Switch to STICK position as Dig control allows the arc characteristics, results in no hot start time. Higher numbers
shown. soft versus stiff, to be changed for specific result in longer start time.
The open circuit voltage is shown in the Left applications and electrodes. Lower the dig
Display with the Volts Indicator lit, and the setting for smooth running electrodes like Press the Setup button to return to adjust-
preset amperage is shown in the Right Dis- E7018 and increase the dig setting for stiff- ment of preset amperage.
play with the Amps Indicator lit. er, more penetrating electrodes like E6010.
Operation Press the Setup Button repeatedly until the . Use this mode for Air Carbon Arc
Arc Control light goes out to return to ad- (CAC−A) cutting and gouging. For best
While the Amps Indicator is lit under the justment of preset amperage. results, adjust dig setting to maximum.
OM-250068 Page 44
9-4. Optional Low Open Circuit Voltage (OCV) Welding Modes
Notes
OM-250068 Page 45
SECTION 10 − MAINTENANCE & TROUBLESHOOTING
3 Months
Replace Repair Or
Damaged Or Replace Replace Cracked
Unreadable Cracked Torch Body
Labels Cables
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
250026-D
OM-250068 Page 46
10-3. Removing Right Side Panel and Measuring Input Capacitor Voltage In 230/460 Volt
Models
! Turn Off welding power
source, and disconnect in-
put power.
4 ! Significant DC voltage can
remain on capacitors after
Typical Bleeder Resistor unit is Off. Always check the
voltage as shown to be sure
25 to 1000 ohm, the input capacitors have
5 watt resistor discharged before working
on unit.
1 Right Side Panel
To remove panel, remove screws
securing panel to unit.
2 Relinking Board PC6
3 Voltmeter
#16 AWG 1000 volts DC
insulation rating, approx. Measure the DC voltage across the
3 in. (76 mm) leads screw terminals on PC6 as shown
1 until voltage drops to near 0 (zero)
volts.
Tools Needed:
5/16 in.
OM-250068 Page 47
10-4. Help Displays
Help 1 Display
Help 2 Display
Help 3 Display
Help 5 Display
Help 6 Display
Help 8 Display
Help 25 Display
OM-250068 Page 48
10-5. Troubleshooting
Trouble Remedy
No weld output; unit completely inop- Place line disconnect switch in On position (see Section 5-10).
erative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-10).
No weld output; meter display On. Input voltage outside acceptable range of variation (see Section 5-9).
Unit overheated. Allow unit to cool with fan On (see Section 4-7).
Erratic or improper weld output. Use proper size and type of weld cable (see Section 5-3).
No 115 volts AC output at optional du- Reset supplementary protector CB1 (see Section 5-7).
plex receptacle.
No 24 volts AC output at Remote 14 Reset supplementary protector CB2 (see Section 5-7).
receptacle.
Notes
OM-250068 Page 49
SECTION 11 − ELECTRICAL DIAGRAM
OM-250068 Page 50
263 256-B
OM-250068 Page 51
SECTION 12 − PARTS LIST
14
7
9 15
11
12 17
6
5 10 13
18
16
3 19
20 22
21
2
4
23
28
24
25
36 31
32 29
37
30
38
26
27
44 43
33
45 34
35
39
40
46 42 41
47
48
49
51
52
87
53 88
86
54
89
55
57
58
59
56 90 96
61 60 95
62 94
93
92
91
63 65 66
64
70
71
56
69
72
68
74
73
81
85
67 82
80 84 75
83
79 76
78 77
250036-E
OM-250068 Page 53
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-1. Parts Assembly
. . . 1 . . . . . . . . . . . . . . 249804 . . Panel, Side Rh W/Nut Insert (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 178551 . . . . Insulator, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 276297 . . . . Label, Warning Match Input Pwr To Voltage (EN/FR/SP) . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 237155 . . . . Label, Important Input Power/Relink Connections . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 249803 . . Panel, Side Lh W/Nut Insert (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 274964 . . . . Label, Warning General Precautionary (EN/FR/SP) . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . +249111 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 135483 . . Label, Important Remove These Two Handle Screws . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . 249848 . . Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . 275316 . . Label, Warning Falling Equipment (EN/FR/SP) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . HD1 . . . . 168829 . . Transducer, Current 1000A Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . L5 . . . . . 254680 . . Cable Assy, Current Feedback W/Ferrite Core . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG 9, 19 . . 115094 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . 183827 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 154408 . . Bushing, Snap−In Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 196355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 14 . . . . . . . . . . . . . . 179276 . . Bushing, Snap−In Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . +249527 . . Windtunnel, Lh W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 219844 . . Label, Warning Electric Shock/Exploding Parts−Wdles . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 249618 . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . RT1 . . . . 199798 . . Thermistor, NTC 30K OHM @ 25 Deg C 18.00In2500V . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 201531 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . 199840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . . 232296 . . Resistor/Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . 204165 . . Heat Sink, Rect Dual Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . T1 . . . . . 263252 . . XFMR, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 249110 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 269262 . . Insulator, Base/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 229325 . . Foot, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . 176736 . . Screw, Mtg Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 28 . . . . PC3 . . . . 246925 . . Circuit Card Assy, Front Pnl & Dspl W/Cover & Label . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG 18 . . . 250065 . . Plug, W/Leads (Voltage Feedback) RC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG 21 . . . 136810 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC 21 . . . 167640 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 230944 . . Cover, Enclosure Connector Db−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . S1 . . . . . 244920 . . Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 231470 . . Nut, Adapter Encoder Shaft Mtg 375−32 To 500−28 . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 176226 . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 274844 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . 251594 . . Panel, Front W/Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . C7, 8 . . . . 222488 . . Capacitor Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . . . . . . . . . 274848 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 216112 . . Fastener, Panel Receptacle Quick Access . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . . . . . 246917 . . Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 43 . . . . . . . . . . . . . . 231469 . . Nut, 500−28 .69Hex .28H Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 174991 . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 . . . . . . . . . . . . . . . . . 2
. . . 45 . . . . . . . . . . . . . . 231468 . . Nut, 375−32 .56Hex .22h Brs Conical Knurl . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 246924 . . Label, Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 246919 . . Door, W/Quick Access Ball Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . . . . . . . . . . Label (Order By Model and Serial Number) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 175138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . PC1 . . . . 260544 . . Circuit Card Assy, Control W/Program 230/460V . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG 2, 5,
. . . . . . . . . 7, 8, 10 . . . 131054 . . Housing Plug+Pins (Service Kit) RC2, 5, 7, 8, 10 . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . PLG 3 . . . 130203 . . Housing Plug+Pins (Service Kit) RC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG 4 . . . 115093 . . Housing Plug+Pins (Service Kit) RC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG 6 . . . 115092 . . Housing Plug+Pins (Service Kit) RC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-250068 Page 54
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-1. Parts Assembly (Continued)
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01