Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
2010−10
Processes
Multiprocess Welding
Description
Auto-Line
™
File: MULTIPROCESS
Mil_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read and follow these precautions.
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
repair this unit. D Frequently inspect input power cord for damage or bare wiring −
replace cord 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 poorly spliced cables.
ELECTRIC SHOCK can kill. D Do not drape cables over your body.
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
electrically live whenever the output is on. The input D Do not touch electrode if you are in contact with the work, ground,
power circuit and machine internal circuits are also or another electrode from a different machine.
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, D Do not touch electrode holders connected to two welding ma-
and all metal parts touching the welding wire are chines at the same time since double open-circuit voltage will be
electrically live. Incorrectly installed or improperly present.
grounded equipment is a hazard. D Use only well-maintained equipment. Repair or replace damaged
D Do not touch live electrical parts. parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Keep all panels and covers securely in place.
or covers big enough to prevent any physical contact with the work D Clamp work cable with good metal-to-metal contact to workpiece
or ground. or worktable as near the weld as practical.
D Do not use AC output in damp areas, if movement is confined, or if D Insulate work clamp when not connected to workpiece to prevent
there is a danger of falling. contact with any metal object.
D Use AC output ONLY if required for the welding process.
D Do not connect more than one electrode or work cable to any
D If AC output is required, use remote output control if present on single weld output terminal.
unit.
D Additional safety precautions are required when any of the follow- SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing electrically hazardous conditions are present: in damp
ing power sources AFTER removal of input power.
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt- HOT PARTS can burn.
age. In most situations, use of a DC, constant voltage wire welder
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 D Allow cooling period before working on equip-
servicing this equipment. Lockout/tagout input power according to ment.
OSHA 29 CFR 1910.147 (see Safety Standards). D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
D Properly install and ground this equipment according to its
clothing to prevent burns.
Owner’s Manual and national, state, and local codes.
OM-2247 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 oil-free protective garments such as leather gloves, heavy
Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
these fumes and gases can be hazardous to your
health. D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D Keep your head out of the fumes. Do not breathe the fumes.
D After completion of work, inspect area to ensure it is free of sparks,
D If inside, ventilate the area and/or use local forced ventilation at the glowing embers, and flames.
arc to remove welding fumes and gases.
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 Material Safety Data Sheets (MSDSs) D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
and the manufacturer’s instructions for metals, consumables, for hot work and have a fire watcher and extinguisher nearby.
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while FLYING METAL or DIRT can injure eyes.
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and D Welding, chipping, wire brushing, and grinding
lower the oxygen level causing injury or death. Be sure the breath- cause sparks and flying metal. As welds cool,
ing air is safe. they can throw off slag.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Wear approved safety glasses with side
erations. The heat and rays of the arc can react with vapors to form shields even under your welding helmet.
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld BUILDUP OF GAS can injure or kill.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements D Shut off shielding gas supply when not in use.
can give off toxic fumes if welded. D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
WELDING can cause fire or explosion. D Wear approved ear protection if noise level is
high.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot CYLINDERS can explode if damaged.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause Shielding gas cylinders contain gas under high
sparks, explosion, overheating, or fire. Check and be sure the area is pressure. If damaged, a cylinder can explode. Since
safe before doing any welding. gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Protect compressed gas cylinders from excessive heat, mechani-
D Do not weld where flying sparks can strike flammable material. cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
D Protect yourself and others from flying sparks and hot metal.
support or cylinder rack to prevent falling or tipping.
D Be alert that welding sparks and hot materials from welding can D Keep cylinders away from any welding or other electrical circuits.
easily go through small cracks and openings to adjacent areas.
D Never drape a welding torch over a gas cylinder.
D Watch for fire, and keep a fire extinguisher nearby. D Never allow a welding electrode to touch any cylinder.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can D Never weld on a pressurized cylinder − explosion will result.
cause fire on the hidden side. D Use only correct shielding gas cylinders, regulators, hoses, and fit-
D Do not weld on closed containers such as tanks, drums, or pipes, tings designed for the specific application; maintain them and
unless they are properly prepared according to AWS F4.1 (see associated parts in good condition.
Safety Standards). D Turn face away from valve outlet when opening cylinder valve.
D Do not weld where the atmosphere may contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-2247 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OM-2247 Page 3
1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
OM-2247 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2010−03
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.
LES RAYONS DE L’ARC peuvent D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
provoquer des brûlures dans les
yeux et sur la peau. D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
génère des rayons visibles et invisibles intense
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
soudage. NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité). DES PIECES DE METAL ou DES
D Porter des lunettes de sécurité avec écrans latéraux même sous
SALETES peuvent provoquer des
votre casque. blessures dans les yeux.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
protéger les autres contre les rayonnements les éblouissements
fil de fer, et le meulage génèrent des étincelles et des particules
et les étincelles ; prévenir toute personne sur les lieux de ne pas métalliques volantes. Pendant la période de refroidissement des
regarder l’arc.
soudures, elles risquent de projeter du laitier.
D Porter des vêtements confectionnés avec des matières résistan- D Porter des lunettes de sécurité avec écrans latéraux ou un écran
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de facial.
protection.
OM-2247 Page 6
LES ACCUMULATIONS DE GAZ LES BOUTEILLES peuvent exploser
risquent de provoquer des blessures si elles sont endommagées.
ou même la mort.
Des bouteilles de gaz protecteur contiennent du gaz
D Fermer l’alimentation du gaz protecteur en cas sous haute pression. Si une bouteille est endom-
de non-utilisation. magée, elle peut exploser. Du fait que les bouteilles
de gaz font normalement partie du procédé de
D Veiller toujours à bien aérer les espaces confi- soudage, les manipuler avec précaution.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) de se renverser.
peuvent affecter les implants médicaux.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Les porteurs de stimulateurs cardiaques
et autres implants médicaux doivent rester D Ne jamais placer une torche de soudage sur une bouteille à gaz.
à distance. D Une électrode de soudage ne doit jamais entrer en contact avec
D Les porteurs d’implants médicaux doivent consulter une bouteille.
leur médecin et le fabricant du dispositif avant de s’approcher D Ne jamais souder une bouteille pressurisée − risque d’explosion.
de la zone où se déroule du soudage à l’arc, du soudage
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
par points, du gougeage, de la découpe plasma
tuyaux et raccords convenables pour cette application spécifique ;
ou une opération de chauffage par induction.
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
LE BRUIT peut endommager l’ouïe. la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffi-
Le bruit des processus et des équipements peut samment de personnes pour soulever et déplacer les bouteilles.
affecter l’ouïe.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
D Porter des protections approuvées pour les l’équipement connexe et le dépliant P-1 de la CGA (Compressed
oreilles si le niveau sonore est trop élevé. Gas Association) mentionné dans les principales normes de sécu-
rité.
OM-2247 Page 7
Les PIÈCES MOBILES peuvent LE RAYONNEMENT HAUTE
causer des blessures. FRÉQUENCE (H.F.) risque de
D Ne pas s’approcher des organes mobiles. provoquer des interférences.
D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut
tels que des rouleaux de commande. provoquer des interférences avec les équi-
pements de radio−navigation et de com-
munication, les services de sécurité et les ordi-
LES FILS DE SOUDAGE peuvent nateurs.
provoquer des blessures. D Demander seulement à des personnes qualifiées familiarisées
D Ne pas appuyer sur la gâchette avant d’en avec des équipements électroniques de faire fonctionner l’installa-
avoir reçu l’instruction. tion.
D Ne pas diriger le pistolet vers soi, d’autres D L’utilisateur est tenu de faire corriger rapidement par un électricien
personnes ou toute pièce mécanique en qualifié les interférences résultant de l’installation.
engageant le fil de soudage. D Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
Les PIÈCES MOBILES peuvent D Maintenir soigneusement fermés les portes et les panneaux des
causer des blessures. sources de haute fréquence, maintenir les éclateurs à une distan-
D S’abstenir de toucher des organes mobiles tels ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de LE SOUDAGE À L’ARC risque de
protection. provoquer des interférences.
D Lorsque cela est nécessaire pour des travaux d’entretien et de D L’énergie électromagnétique risque de
dépannage, faire retirer les portes, panneaux, recouvrements provoquer des interférences pour l’équipement
ou dispositifs de protection uniquement par du personnel qua- électronique sensible tel que les ordinateurs et
lifié. l’équipement commandé par ordinateur tel que
D Remettre les portes, panneaux, recouvrements ou dispositifs de les robots.
protection quand l’entretien est terminé et avant de rebrancher
D Veiller à ce que tout l’équipement de la zone de soudage soit
l’alimentation électrique.
compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
LIRE LES INSTRUCTIONS. soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
D Lire et appliquer les instructions sur les
D Veiller à souder à une distance de 100 mètres de tout équipe-
étiquettes et le Mode d’emploi avant l’instal-
ment électronique sensible.
lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du D Veiller à ce que ce poste de soudage soit posé et mis à la terre
manuel et dans chaque section. conformément à ce mode d’emploi.
D N’utiliser que les pièces de rechange recommandées par le D En cas d’interférences après avoir pris les mesures précéden-
constructeur. tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentaires telles que le déplacement du poste, l’utilisation de câ-
D Effectuer l’entretien en respectant les manuels d’utilisation, les bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
normes industrielles et les codes nationaux, d’état et locaux. teurs dans la zone de travail.
OM-2247 Page 8
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org).
Internet : www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,
and Cutting, American Welding Society Standard AWS F4.1, de Global P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
Engineering Documents (téléphone : 1-877-413-5184, site internet : site Internet : www.nfpa.org).
www.global.ihs.com).
OSHA, Occupational Safety and Health Standards for General
National Electrical Code, NFPA Standard 70, de National Fire Protec- Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
tion Association, Quincy, MA 02269 (téléphone : 800-344-3555, site Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing
Internet : www.nfpa.org et www.sparky.org). Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, 15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan- régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
tilly, VA 20151 (téléphone : 703-788-2700, site Internet : Internet : www.osha.gov).
www.cganet.com). U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Safety in Welding, Cutting, and Allied Processes, CSA Standard Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site inter-
W117.2, de Canadian Standards Association, Standards Sales, 5060 net : www.cpsc.gov).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone : Applications Manual for the Revised NIOSH Lifting Equation, The
800-463-6727, site internet : www.csa-international.org). National Institute for Occupational Safety and Health (NIOSH), 1600
Safe Practice For Occupational And Educational Eye And Face Protec- Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
tion, ANSI Standard Z87.1, de American National Standards Institute, www.cdc.gov/NIOSH).
OM-2247 Page 9
OM-2247 Page 10
SECTION 3 − INTRODUCTION
3-1. Specifications
RMS Amps Input at Rated Load Output,
Max. 60 Hz 3-Phase at NEMA Load Voltages
Amperage Open- and Class I Rating
Input Voltage Range in Circuit
Power Rated Output Range in CV Mode CC Mode Voltage 208 V 230 V 400 V 460 V 575 V KVA KW
3-Phase 350 A at 34 10−38 V 5−425 A 75 VDC 40.4 36.1 20.6 17.8 14.1 14.2 13.6
VDC, 60%
Duty Cycle
1-Phase 300 A at 32 60.8 54.6 29.7 25.4 19.9 11.7 11.2
VDC, 60%
Duty Cycle*
*See Section 3-3 for Duty Cycle Rating.
80
70
60
VOLTS
50 SMAW GTAW
MAX MAX
40
30 GTAW
SMAW
80A
MN
20 0% ARC
CONTROL
25%
10 50%
75%
100%
0
0 100 200 300 400 500
AMPERAGE
B. CV Mode
100
90
80
70
60
VOLTS
50
MAX
40
30
20
MIN
10
0
0 100 200 300 400 5 00
AMPERAGE
217 836-A / 217 837-B
OM-2247 Page 11
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed and
cooling fan runs. Wait fifteen min-
utes for unit to cool. Reduce amper-
age or voltage, or duty cycle before
welding.
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
Ref. 216 568-A
Notes
OM-2247 Page 12
SECTION 4 − INSTALLATION
24 in.
(610 mm)
Dimensions And Weight
80 lb (36.3 kg)
17 in.
(432 mm)
12-1/2 in.
(318 mm)
Location
3
18 in.
(460 mm)
18 in.
(460 mm) loc_2 3/96 - Ref. ST-151 556 / Ref. 803 879-B
OM-2247 Page 13
4-3. Connecting 1-Phase Input Power
! Installation must meet all Na-
tional and Local Codes − have
only qualified persons make
this installation.
! Disconnect and lockout/tag-
out input power before con-
1 necting input conductors from
unit.
! Always connect green or
8 green/yellow conductor to
=GND/PE
supply grounding terminal
Earth
first, and never to a line termi-
Ground
nal.
10
. The Auto-Line circuitry in this unit
automatically adapts the power
source to the primary voltage be-
ing applied. Check input voltage
available at site. This unit can be
7 connected to any input power be-
tween 208 and 575 VAC without
removing cover to relink the pow-
9 er source.
1 Black And White Input
Conductor (L1 And L2)
L1 2 Red Input Conductor
1
L2 3 Green Or Green/Yellow
Grounding Conductor
3 4 Insulation Sleeving
1
5 Electrical Tape
Insulate and isolate red conductor as
shown.
2 6 Input Power Cord.
6 7 Disconnect Device (switch
3
shown in the OFF position)
8 Disconnect Device Grounding
6 Terminal
9 Disconnect Device Line
4 Terminals
5
Connect green or green/yellow
grounding conductor to disconnect
device grounding terminal first.
Connect input conductors L1 and L2
to disconnect device line terminals.
10 Overcurrent Protection
Select type and size of overcurrent
protection using Section 4-5 (fused
disconnect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout de-
vice, and place switch in the On posi-
tion.
Tools Needed:
804 531-A
OM-2247 Page 14
4-4. Connecting 3-Phase Input Power
! Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
! Disconnect and lockout/tagout in-
3 put power before connecting input
conductors from unit.
! Always connect green or green/
yellow conductor to supply
= GND/PE Earth Ground grounding terminal first, and never
to a line terminal.
4
. The Auto-Line circuitry in this unit au-
tomatically adapts the power source
to the primary voltage being applied.
7 Check input voltage available at site.
This unit can be connected to any in-
put power between 208 and 575 VAC
without removing cover to relink the
power source.
2 For Three-Phase Operation
1 Input Power Cord.
2 Disconnect Device (switch shown in
the OFF position)
3 Green Or Green/Yellow Grounding
Conductor
L1
4 Disconnect Device Grounding
3 L2 5 Terminal
6 L3 5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3
1 to disconnect device line terminals.
7 Overcurrent Protection
Select type and size of overcurrent protec-
tion using Section 4-5 (fused disconnect
switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
804 531-A
OM-2247 Page 15
4-5. Electrical Service Guide
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
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 branch circuit sized for the rated output and duty cycle of the welding power source.
Single-Phase
Input Voltage (V) 208 230 400 460 575
Input Amperes (A) At Rated Output 60.8 54.6 29.7 25.4 19.9
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 70 60 35 30 25
Normal Operating Fuses 3 80 80 45 40 30
Min Input Conductor Size In AWG/Kcmil 4 8 8 10 12 12
72 89 176 140 219
Max Recommended Input Conductor Length In Feet (Meters)
(22) (27) (54) (43) (67)
Min Grounding Conductor Size In AWG/Kcmil 4 8 8 10 12 12
Three-Phase
Input Voltage (V) 208 230 400 460 575
Input Amperes (A) At Rated Output 40.4 36.1 20.6 17.8 14.1
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 45 40 25 20 15
Normal Operating Fuses 3 60 50 30 25 20
Min Input Conductor Size In AWG/Kcmil 4 8 10 12 14 14
119 96 175 150 234
Max Recommended Input Conductor Length In Feet (Meters)
(36) (29) (53) (46) (71)
Min Grounding Conductor Size In AWG/Kcmil 4 10 10 12 14 14
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 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-2247 Page 16
4-6. Weld Output Receptacles And 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***
Weld Output
Terminals
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)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (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-G 2009−08
OM-2247 Page 17
4-7. Remote 14 Receptacle Information
M CC/CV select
2 3
803 691-C
OM-2247 Page 18
‘
OM-2247 Page 19
SECTION 5 − OPERATION
FCAW
6 5 7
OM-2247 Page 20
5-2. Meter Functions
. The meters display the actual weld output values for approximately three seconds after the arc is broken.
. The Stick and CC modes provide the Adaptive Hot Start™ feature, which automatically increases the output amperage at the start of a weld should
the start require it. This eliminates electrode sticking at arc start.
V-Sense Feeder MIG (GMAW) With Voltage Sensing Wire Feeder Electrode Hot
OM-2247 Page 21
5-4. Lift-Arc TIG Procedure
With Process Switch in the Lift-Arc
TIG position, start an arc as follows:
1 TIG Electrode
2 Workpiece
Touch tungsten electrode to work-
piece at weld start point, hold
electrode to workpiece for 1-2
seconds, and slowly lift electrode.
An arc will form when electrode is
1 2 lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
1−2
“Touch” Seconds solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with-
out overheating, sticking, or getting
contaminated.
OM-2247 Page 22
SECTION 6 − 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
OM-2247 Page 23
6-3. Voltmeter/Ammeter Help Displays
. All directions are in reference to
the front of the unit. All circuitry
referred to is located inside the
V A unit.
Help 1 Display
V A
Help 2 Display
V A
Help 3 Display
V A
Help 5 Display
V A
Help 6 Display
V A
Help 8 Display
OM-2247 Page 24
6-4. Troubleshooting
Trouble Remedy
No weld output; unit completely inop- Place line disconnect switch in On position (see Sections 4-3 and 4-4).
erative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Sections 4-3 and 4-4).
Check for proper input power connections (see Sections 4-3 and 4-4).
No weld output; meter display On. Input voltage outside acceptable range of variation (see Section 4-5).
Unit overheated. Allow unit to cool with fan On (see Section 3-3).
Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-6).
No 115 volts AC output at optional du- Reset supplementary protector CB1 (see Section 4-8).
plex receptacle or Remote 14 recep-
tacle.
No 24 volts AC output at Remote 14 Reset supplementary protector CB2 (see Section 4-8).
receptacle.
OM-2247 Page 25
SECTION 7 − ELECTRICAL DIAGRAM
OM-2247 Page 26
246 067-A
OM-2247 Page 27
14 32
24 30 31
11
OM-2247 Page 28
8 12 77 29
15 28
6
16
25
5
13 19 23 34
9
20 35
4 26
17
10 18
38 37
3 39
75 40
36
22
76 41
21 42
58 57
43
44
63 45
64 17
51 47
1 56 MOD 2
2
65 50
MOD 1
66 52 49
62 53
74
54
55
68
70
71
72
73
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 115V Aux Power Option. (Not Available On French Units)
♦♦Part of Tweco Type Connector Option. (Not Available On French Units)
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2247 Page 29
Item Dia. Part
No. Mkgs. No. Description Quantity
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 115V Aux Power Option. (Not Available On French Units)
♦♦Part of Tweco Type Connector Option. (Not Available On French Units)
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2247 Page 30
Item Dia. Part
No. Mkgs. No. Description Quantity
. . . 62 . . . . . . . . . . . . ♦♦218 183 . . Rcpt Assy, Tw Lk Insul Fem (Tweco Type) (Fac-op) (Includes) . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 209 473 . . . . Receptacle, Twist Lock Tweco Style (Female) Power . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 712 . . . . Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 713 . . . . Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 714 . . . . Washer, Tooth 22Mmid X 31.5Mmod 1.310-1Mmt Intern . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 717 . . . . Nut, M20-1.5 1.00Hex .19H Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 718 . . . . O-Ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 186 228 . . . . O-Ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . 212 070 . . Panel, Front Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . C6,7 . . . . . 214 749 . . Capacitor Assy, W/Plug & Leads (Voltage Feedback) . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . 216 112 . . Fastener, Panel Receptacle Quick Access . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 66 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Connection (Order by Model and Serial Number) . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Power (Order by Model and Serial Number) . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . . 174 991 . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 . . . . . . . . . . . . . . . 2
. . . 70 . . . . . . . . . . . . . . . 174 992 . . Knob, Pointer .840 Dia X .250 Id W/Spring Clip−.21 . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . . 239 916 . . Label, Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . . 218 041 . . Door, W/Quick Access Ball Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . . 175 138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . . . . . . . . . . . . . Label, (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . +212 207 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . . 211 503 . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . . 227 746 . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 115V Aux Power Option. (Not Available On French Units)
♦♦Part of Tweco Type Connector Option. (Not Available On French Units)
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2247 Page 31
5 1
3 3
12
1
7
View of RH Windtunnel
4 4
2
12
16 9
8
Label (6) located on
15 top of Windtunnel.
6
10 13
11 14
Item Part
No. No. Description Quantity
Figure 8-2. Wrapper/Label Location - French Units
... 1 . . . . . . . . . . . . . . . 218 545 . . Label, Warning Exploding Parts Can Serious Inj (French) . . . . . . . . . . . . 2
... 2 . . . . . . . . . . . . . . . 126 026 . . Label, Warning Electric Shock Can Kill Significant . . . . . . . . . . . . . . . . . . 2
... 3 . . . . . . . . . . . . . . . 218 542 . . Label, Important Remove These Two Handle Screws (French) . . . . . . . 2
... 4 . . . . . . . . . . . . . . . 217 136 . . Label, Warning Electric Shock (English/French) . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . . . . . . 218 541 . . Label, Caution Falling Equip Can Cause Injury (French) . . . . . . . . . . . . . 2
... 6 . . . . . . . . . . . . . . . 218 544 . . Label, Warning Electric Shock Can Kill (French) . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . . 244 870 . . Label, Process (French) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......................... Nameplate, (French) (Order by Model and Serial Number) . . . . . . . . . . . 1
... 9 .......................... Nameplate, Rear (French) (Order by Model and Serial Number) . . . . . . 1
... 10 .......................... Nameplate, Connection/CE (Order by Model and Serial Number) . . . . . 1
... 11 .......................... Nameplate, Power/CE (Order by Model and Serial Number) . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . . 220 022 . . Label, Warning Electric Shock Can Kill (French) . . . . . . . . . . . . . . . . . . . . 2
... 13 . . . . . . . . . . . . . . . 220 023 . . Label, Warning Incorrect Connections (French) . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . . 217 480 . . Label, Warning Incorrect Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .......................... Label, (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . . . 221 787 . . Wrapper (Includes Insulators and Safety Labels) (French) . . . . . . . . . . . 1
OM-2247 Page 32
Notes
229895
MATERIAL THICKNESS GAUGE
Notes
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 © 2010 Miller Electric Mfg. Co. 2010−01