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Miller Electric EXTREME 360 User's Manual

1. Delos uri eM a RT ware BE 185 713 Insulator Bulkhead Rear SR RENTRER AA 185 714 Washer Tooth 22Mmid X 31 5Mmod 1 310 1Mmt Intern 1 eatin ns 185 717 Nut M20 1 5 1 00Hex 19H Brs Locking 1 amen ETE 185 718 O Ring 0 989 Id X 0 070 H aras me a ASE quae 186228 O Ring 0 739 Id X 0 070 H 1 SUO Xuan a ves 212070 Panel Front Standard 1 64 C6 7 214749 Capacitor Assy W Plug amp Leads Voltage Feedback 1 OD rire Dade 216 112 Fastener Panel Receptacle Quick Access 2 GOR duni ur Ru Nameplate Order by Model and Serial Number 1 eae o mn pie eG Nameplate Connection Order by Model and Serial Number 1 pa OB rr etes ans Nameplate Power Order by Model and Serial Number 1 3 69 nct iae tuna 174991 Knob Pointer 1 250 Dia X 250 Id W Spring Clip 21 2 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 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 229 409 Page 30 No Mkgs No De
2. Mode Meter Reading At Idle Meter Reading While Welding V A V A cones 71 7 85 10 3 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A Lift Arc TIG 14 1 85 10 3 85 Actual Volts Preset Amps Actual Volts Actual Amps V A V A TIG 85 10 3 85 Blank Preset Amps Actual Volts Actual Amps V A V A MIG 24 5 24 5 250 Preset Volts Blank Actual Volts Actual Amps V A V A i PPP PPP 24 5 250 Pulse Display Pulse Display Actual Volts Actual Amps V A V A cc 85 24 5 85 Blank Preset Amps Actual Volts Actual Amps V A V A Stick 71 7 85 24 5 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A c 71 7 24 5 250 Flashes OCV And Preset Blank Actual Volts Actual Amps 5 3 Mode Switch Settings 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 Mode Switch Setting Process Output On Off Control Scratch Start TIG GTAW Electrode Hot Lift Arc TIG GTAW See Section 5 4 Electrode Hot TIG GTAW With HF Unit Pulsing Device Or Remote Control At Remote 14 MIG GMAW At Remote 14 Pulsed MIG GMAW P Requires an external pulsing device At Remote 14 CC Stick SMAW With Remote On Off At Remote 14 Stick SMAW Electrode Hot V Sense Feeder MIG GMAW With Voltage Sensing Wire Feeder Electrode Hot OM
3. 1 2O T az 212132 XFMR HF Litz Litz W Boost 1 zelus euet 225097 Heat Sink Lh Rect 1 OA reu ax Et us 212091 2 Inductor Inp t mer er tar an Net ERA 1 VAS be action 083 147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 4 24 POT o 218 007 Circuit Card Assy Control W Program 1 ead css PC1 223 656 Circuit Card Assy Control Aux Power W Program 1 quce 216 113 Stand Off Support PC Card 187 Dia W P amp l 375 2 PLG1 115091 Housing Plug Pins Service Kit RC1 1 denied nae PLG2 201 665 Housing Plug Pins Service Kit RC2 PLGS 131 056 Housing Plug Pins Service Kit RC3 1 m PLG5 191 204 Housing Plug Pins Service Kit RCB 1 TN PLG7 191 054 Housing Plug Pins Service Kit RC7 1 ze oka unus PLG8 191 054 Housing Plug Pins Service Kit RC8 1 PLG9 115093 Housing Plug Pins Service Kit RC9 EET PLG10 115094 Housing Plug Pins Service Kit RC10 1 E PLG11 115094 Housing Plug Pins Service Kit RC11 1 PLG12 115092 Housing P
4. 21 5 4 LBt Arc TIG Procedut Armer nternet ene ded EE UST ENS 22 5 5 Stick Start ProcedU r on eneen beard e aleen RR ede RR DS RR AUR Ae RR 22 SECTION 6 MAINTENANCE amp TROUBLESHOOTING eeeeeee nn 23 6 1 Routine Maintenance cesse ra weeen aat eh dgn pete hip Rb pode ER ACE eS 23 6 2 Blowing Out Inside Of Unit eenen 23 6 3 Voltmeter Ammeter Help Displays 24 6 4 Troubleshooting aar ved lane sars ged dace an pd S ROPA ER be aed EURO ot de td Eee ass Cha oa 24 SECTION 7 ELECTRICAL 5 26 SECTION 8 PARTS LIST ip ny ee de rieten ee sun etre amas EE E eae db etais 28 WARRANTY Welderentals 1 800 245 3660 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2007 04 A Protect yourself and others from injury read and follow these precautions 1 A A 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A A
5. Items furnished by manufacturer but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than manufacturer or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MANUFACTURER S PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at manufacturer s option 1 repair or 2 replacement or where authorized in writing by manufacturer in appropriate cases 3 the reasonable cost of repair or replacement at an authorized service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Manufacturer s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at an authorized service facility as determined by manufacturer Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REME
6. Le The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill n Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote out
7. riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage OM 229 409 Page 5 reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures gt LES FUM ES ET LES GAZ peuvent tre dangereux I Le soudage g n re des fum es et de
8. zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SA o LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement
9. 229 409 Page 21 5 4 Lift Arc TIG Procedure EN N With Process Switch in the Lift Arc CR Z sua lt TIG position start an arc as follows mi r MY 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 R lifted a Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between 1 2 electrode and workpiece The 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 Do NOT Strike Like A Match Ref S 156 279 5 5 Stick Start Procedure pe E CR 9 DE With Stick selected start arc as fol PA Wy 48 ws MM zu S AL Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc 1 goes out electrode was lifted to high 2 If electrode sticks to workpiece use LT 7 a quick twist to free it j n x lt Low OCV Stick The unit can be optionally config 2 ured for low open circuit voltage lt 4 OCV operation When the unit is PES configured for low OCV operation Toa onl
10. 8 Pour les moteurs essence 4 Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel 4 Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario
11. Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi
12. D 153 178 Label Warning Exploding Parts Can Serious Injury 1 DO sis s ba ates 212074 Bus Bar Output 1 bos cues HD1 182918 Transducer Current 400A Module Supply V 15V 1 PC3 218008 Circuit Card Assy Front Panel amp Display W Program 1 PLG18 181204 Housing Plug Pins Service Kit RC2 DA RC50 210233 Rept W Pins Service Kit CRI PRU PEG21 212 088 Pl g Wi Le ds eee tetes Er resa eee ERR eie ts 1 RC21 167 640 Housing Plug Pins Service Kit pe OO ewan Sil copas 231 191 Switch Tgl 3Pst 50A 600VAC Scr Term Wide Tgl 1 ND C Ree 176226 Insulator Switch Power 1 te 9T s FM1 196 313 Fan Muffin 115V 50 60Hz 3000 Rpm 6 378 Mtg Holes 1 PLG16 181054 Housing Plug Pins Service Kit Ur Gaia RC16 135635 Housing Plug Pins Service Kit sis DP aee eus 218183 Rcpt Assy Tw Lk Insul Fem Tweco Type Fac op Includes 2 SR Eu Ra E DES 209 473 Receptacle Twist Lock Tweco Style Female Power 1 decr cb AT tO 185 712 Insulator Bulkhead Front
13. Id X1 375 Mtg Hole 1 SO m 219487 Cable Power 12 Ft 8Ga 4C Non Stripped End 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 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 229 409 Page 29 No Mkgs No Description Quantity Figure 8 1 Parts Assembly Continued RE TOEN EEE 234 126 Nut Conduit 1 000 Npt Knurled 1 oO rns 211 109 XFMR Control 665V 336Va Syn Aux Pwr 1 DO qais T2 211 968 XFMR Control Toroidal 665 VAC Pri 1536 Va 60 Hz 1 MI CP E 212 947 Plate Mtg Toroid XFMR 1 OO e us 218018 Inductor Pre Regulator 1 AO erste eos 218566 Gasket Inductor Mounting 1 odd os OTT aues 196 231 XMFR Current Sensing 200 1 1 AD ses C15 196 143 Capacitor Polyp Met Film 16 Uf 400 VAC 10 1 xu Mes penu 216 117 Bracket Mtg Capacitor Series 1 44 RT2 199 798 Thermistor Ntc 30K Ohm 25 Deg C 18in Lead 1 et AD es Led PC2 225442 Circuit Card Assy Interconnect W Label amp Cli
14. Single Phase Input Voltage 208 230 400 460 575 Input Amperes At Rated Output 60 8 54 6 29 7 25 4 19 9 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 70 60 35 30 25 Normal Operating 3 80 80 45 40 30 Min Input Conductor Size In AWG Kcmil 4 8 8 10 12 12 Max Recommended Input Conductor Length In Feet Meters en 64 d 67 Min Grounding Conductor Size In AWG Kcmil 4 8 8 10 12 12 Three Phase Input Voltage 208 230 400 460 575 Input Amperes At Rated Output 40 4 36 1 20 6 17 8 14 1 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 45 40 25 20 15 Normal Operating 60 50 30 25 20 Min Input Conductor Size In AWG Kcmil 4 8 10 12 14 14 Max Recommended Input Conductor Length In Feet Meters 0 ea E de m Min Grounding Conductor Size In AWG Kcmil 4 10 10 12 14 14 Reference 2005 National Electrical Code NEC including article 630 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 On 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 fle
15. control setting 7 Arc Control Control adjusts Dig when Stick or CC mode is selected on mode switch When set towards minimum short circuit amperage at low arc voltage is the same as normal welding amperage When set towards maximum short circuit amperage is increased at low arc voltage to assist with arc starts as well as reduce stick ing while welding Select setting best suited for application Control adjusts inductance when MIG or V Sense Feeder position is selected on the mode switch Inductance determines the wetness of the weld puddle When set to wards maximum wetness puddle fluidity increases When Pulsed MIG or one of the TIG modes is selected this control is not functional 2 3 4 7 O V A V A ADJUST 40 50 eo LIFFARGn stick 70 80 GF V SENSE START FEEDER 90 TIG REMOTE Ref 803 692 B Ref 212 064 OM 229 409 Page 20 5 2 Meter Functions L The meters display the actual weld output values for approximately three seconds after the arc is broken
16. e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl menta
17. le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution
18. org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de Vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 229 409 Page 9 OM 229 409 Page 10 SECTION 3 INTRODUC
19. then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2007 04 4 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc 4 Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit gt Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil gt Pendant le f
20. 1 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip RED D ARC Welderentals 1 800 245 3660 www red d arc com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA 1 07
21. 3 0 3 4 0 3 4 0 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 For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 mm for metric use S 0007 F OM 229 409 Page 17 4 7 Remote 14 Receptacle Information 7 REMOTE Socket Socket Information t ircuit k B2 24 VOLTS AC A 24 volts ac Protected by circuit breaker C OUTPUT B Contact closure to A completes 24 volts ac CONTACTOR contactor control circuit 115 VOLTS AC l 115 volts ac Protected by circuit breaker CB1 OUTPUT J Contact closure to completes 115 volts ac CONTACTOR contactor control circuit C Output to remote control 0 to 10 volts dc 10 volts dc in MIG mode REMOTE D Remote control circuit common OUTPUT CONTROL E O to 10 volts dc input command signal from remote control M CC CV select AN F Current feedback 1 volt dc per 100 amperes AMPERAGE H Voltage feedback 1 volt dc per 10 output recep VOLTAGE tacle volts G Circuit common for 24 and 115 volts ac circuits GND Chassis common The remaining sockets are not used 4 8 Optional 115 Volts AC Duplex Receptacle And Circuit Br
22. DIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MANUFACTURER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MANUFACTURER IS EXCLUDED AND DISCLAIMED BY MANUFACTURER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province brand_warr 2007 0
23. Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shutoff shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator MAGNETIC FIELDS can affect Implanted Medical Devices 9 Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder
24. OM 229 409E 2007 11 A Processes oo 7 Multiprocess Welding RED D ARC Description Welderentals ELLE 1 800 245 3660 EXTREME 360 CC CV Auto Line OWNER S MANUAL TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Testi Symbol Usage isse Enc dende FR ea HER RR arke 1 1 2 Arc Welding Hazards anne 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 2 4 1 5 Principal Safety Standards 2 4 162 EMF Information 22 2 i cix met us aus iens eR UNE EUM Eu MEE NE baba iss 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles UTIISES eras he Patate eps ape ur aus de eus haqq E que RR eliene 5 2 2 Dangers relatifs au soudage l arc 5 2 8 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Information EMF err nc PR EIE Ra KE up RPIIGMEX E PPECRnR ESOS 9 SECTION 3 INTRODUCTION 2828 xx que sees sent den
25. OT e VAL NEUTRAL K GND lt 42 l l sess sem n d i RCBO A 23VAC 36 5 57 e i RCSO I 115VAC 67 sa GG gt RC50 G 23 115VAC NEUTRAL 4 s4 3 Qi N N S RC50 K CHASSIS GND 42 d 1 aj a 7 2 A A A A A A A gt RC50 J 115V RMT CONT qom qoc OT g d NS ON GRON uc gt RC50 B 24V RMT CONT 2282232532323 gt RC50 E REF IN RC51 gt RC50 C REF OUT jn gt RC50 F 1V 100A gt RC50 D REF COM gt RC50 H 1V 10V RCI RCE gt RC50 M CC CV SEL PCS FRONT PANEL amp DISPLAY RC2 PLG18 RC2 5 gt gt I RC2 1 gt gt Figure 7 1 Circuit Diagram OM 229 409 Page 26 211 328 F Lu gt E lJ ZO a O 5 8 1 CE s J DO S B x a gt a X gt V x gt 5 E E a ES 4 a Pe al aN 2l e N l l c ul a k le AN Zal Uu amp o lt 2 Fu E S 9 55 Or n lt 4 a ES 2 p NS H He w S RSS As 1 o Y v q l l 3 oe 22 rr o O o a a a OO ec 5 P 9 9 I L E 22 FID TIT zi
26. TION 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 208V 230V 400V 460V 575V KVA KW 3 Phase 350 A at 34 10 38 V 5 425 A 75VDC 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 3 2 Volt Ampere Curves A CC Mode Volt ampere curves show minimum and maximum voltage and amper 100 age output capabilities of welding power source Curves of other set 90 tings fall between curves shown 80 70 a 604 H 1 o 50 SMAW GTAW gt 40 MAX MAX 304 ataw MN 20 ARC 2596 CONTROL 104 04 r Tl 0 100 200 300 400 500 AMPERAGE B CV Mode 100 90 80 70 o 60 9 50 40 30 20 10 0 0 100 200 300 400 500 AMPERAGE 217 836 A 217 837 B OM 229 409 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 o
27. TION TABLE U S STANDARD METRIC Specifications Socket or Wrench Size Specifications Socket or Wrench Size U S Dens Elden Bot ND Band Euver Bolt mat 1 4 in 250 in 3 8 in 7 16 in 6mm 2362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 6 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13 16 in 14 mm 5512 in 22mm 22 mm 9 16 in 5625 in 7 8 in 7 8 in 16 mm 6299 in 24 mm 24 mm 5 8 in 625 in 15 16 in 1in 18 mm 7087 in 27 mm 27 mm 3 4 in 750 in 1 1 8 in 1 1 8 in 22mm 8661 in 32 mm 32 mm 7 8 in 875 in 1 5 16 in 1 5 16 in 24 mm 9449 in 36 mm 36 mm 1in 1 000 in 1 1 2 in 1 1 2 in Notes 24 GA 0239 O 22 GA 0299 m 20 GA 0359 18 GA 0478 16 G 0598 14 GA C 0747 1 8 C 125 229895 10 GA 1345 3 16 0 1875 1 4 250 5 16 3125 024 030 035 MATERIAL THICKNESS GAUGE Warranty Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warra
28. between 208 and 575 VAC without removing cover to relink the power source For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 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 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 804 531 A OM 229 409 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 1096 less than minimum and or 1096 more than maximum input voltages listed in table If actual input voltage is outside this range output may not be be available A 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
29. ctions 4 3 and 4 4 No weld output meter display On Input voltage outside acceptable range of variation see Section 4 5 Check repair or replace remote control 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 Clean and tighten all weld connections Check for correct polarity No 115 volts ac output at optional du Reset circuit breaker CB1 plex receptacle or Remote 14 recep tacle No 24 volts ac output at Remote 14 re Reset circuit breaker CB2 ceptacle OM 229 409 Page 24 Notes HEART WELDING TECHNOLOGY I Start Your Professional 55 4 Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 OM 229 409 Page 25 SECTION 7 ELECTRICAL DIAGRAM A WARNING Do not touch live electrical parts tft Disconnect input power or stop 5 f eji engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit GRN VEL Lt oc o l l 3 0 WIG 2 l 1 pese a u 0 2577 9 7 OPTIONAL RC2 115V RCPT 51 01722 H
30. ded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual 9 Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power ne Turn Off inver
31. e Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor
32. e sone eta E sama apus E 11 3 1 Specificalions u u u ER Ped p Rupe is od nee ede ar nn ns au Rod RU dans 11 3 2 WVoltAmpere Curves u u van RR rx eoe gar da ans date acere ac aman che ae nn ete LAN C 11 3 3 Duty Cycle And Overheating 444222 4 12 SECTION 4 INSTALLATION jk ae ag i ed ie RR AER RI RE nanas est 13 4 1 Dimensions And Weight 4 82 13 4 2 Selectinga Location oaeen 18 4 3 Connecting 1 Phase Input Power 14 4 4 Connecting 3 Phase Input Power 15 4 5 Electrical Service Guide rrii eate rarei enen 16 4 6 Weld Output Receptacles And Selecting Cable Sizes 17 4 7 Remote 14 Receptacle Information eee 18 4 8 Optional 115 Volts AC Duplex Receptacle And Circuit Breakers 18 4 9 Optional Gas Valve Operation And Shielding Gas Connection 19 SECTION 5 OPERATION 257 eins de DERI ce 20 5 1 Front Panel Controls s iie obras DA RO URSINI UE EO Ao eoi fe da ss 20 5 2 Meter Functions verc bid Eb entr nb weta eneen PP EE EE EE 21 5 3 Mode Switch Settings s ee Lr eh UG EN bad bie
33. eakers 1 115V 10 Amp AC Receptacle Power is shared between duplex receptacle and Remote 14 recep tacle see Section 4 7 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects duplex receptacle and 115 volts ac portion of Remote 14 receptacle from overload CB2 protects 24 volts ac portion of Remote 14 receptacle from overload Press button to reset breaker 803 691 C OM 229 409 Page 18 4 9 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 Oylinder 2 Regulator Flowmeter Install so face is vertical 3 Gas Hose Connection Fitting has 5 8 18 right hand threads Obtain and install gas hose 4 GaslnFitting 5 Gas Out Fitting The Gas In and Gas Out fittings have 5 8 18 right hand threads Obtain proper size type and length hose and make connections as 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 Gas flow stops at end of post flow if current was detected or with re
34. ed covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 229 409 Page 2 lt Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them
35. eeds 4 Line Disconnect Device Locate unit near correct input power supply A Special installation may be Location required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 loc 2 3 96 Ref ST 151 556 Ref 803 691 C OM 229 409 Page 13 4 3 Connecting 1 Phase Input Power Per Tools Needed Nn GND PE Earth Ground A A A 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 necting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line termi nal 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 connected to any input power be tween 208 and 575 VAC without removing cover to relink the pow er source Black And White Input Conductor L1 And L2 2 Red Input Conductor 3 Green Or Green Yellow Grounding Conductor 4 Insulation Sleeving 5 Electrical Tape Insulate and isolate red conductor as shown 6 Input Power Cord 7 Disconnect Device switc
36. elding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 229 409 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Saf
37. fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante P gt Indique des instructions sp cifiques e 2 Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mett
38. forks are long enough to extend beyond opposite side of unit T OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit nn nn e d F N FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N 3 e Puton grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards SS e MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire Lj STATIC ESD can damage PC boards B MOVING PARTS can cause injury NU e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in
39. h shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals 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 804 531 A OM 229 409 Page 14 4 4 Connecting 3 Phase Input Power Per P 7 2 5 GND PE Earth Ground E Tools Needed SN G A Installation must meet all National and Local Codes have only quali fied persons make this installation A Disconnect and lockout tagout in put power before connecting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal gt The Auto Line circuitry in this unit au tomatically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to any in put power
40. he unit has shut down to allow the fan to cool it see Section 3 3 Operation will continue when the unit has cooled 4 Help 5 Display Indicates the right side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 3 3 Operation will continue when the unit has cooled current limit As the line voltage decreases the required input current increases If the line voltage is too low the output power is limited by the input current When this limit is reached the unit automatically reduces out put power to continue operation If this display is shown have a qualified electrician check the input voltage 6 Help 8 Display Indicates a malfunction in the thermal protec tion circuitry If this display is shown contact a Factory Authorized Service Agent Indicates a malfunction in the secondary power circuit of the unit If this display is shown contact a Factory Authorized Service 5 Help 6 Display Indicates operation at maximum input cur 3 Help 3 Display rent The unit has a maximum allowable input Agent 6 4 Troubleshooting 9 gt r r es lt RS 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 Se
41. her l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que t
42. ires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Enn L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT pa e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal E e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste KF LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l q
43. l Precautionary Static Wire Feed QUO Reda Dis 138442 Label Caution Falling Equip Can Cause Injury D E 195585 Handle Rubberized Carrying 20D 135 483 Label Important Remove These Two Handle Screws 6 R3 C4 233 052 Resistor Capacitor Tr tn etna Phara Br co MDC ETT Se Or uera SR1 201 530 Kit Diode Fast Recovery Bridge Er dm 199840 Bus Bar Diode 196 355 Insulator Screw 11 D1 D2 201 531 Kit Diode Power Module xd vis RT1 199 798 Thermistor NTC 30K Ohm 25 Deg C 18In Lead CR1 198 549 Relay Encl 24VDC Spst 35a 300VAC 4pin Flange Mtg E ce 227 127 Label Warning Electric Shock Exploding Parts 010546 Bushing Snap In Nyl 375 Id X 500 Mtg Hole 1 16 L4 218020 Inductor Boost 1 ONT Sun epee 179 276 Bushing Snap In Nyl 1 000 Id X 1 375 Mtg Hole Cent 3 ai 170 647 Bushing Snap In Nyl 1 312 Id X 1 500 Mtg Hole 1 3 d95 isis LS 212150 Inductor Output
44. lug Pins Service Kit RC12 1 20 csse 212072 Bracket Mtg Capacitor Pc Board 1 26 C12 13 219930 Kit Capacitor Elctlt Replacement Includes 1 ROUTER 193 738 Capacitor Elctlt 1800 Uf 500 VDC Can 2 52 Dia 2 baal 217040 Nut Nylon M12 Thread Capacitor Mounting 2 m EA RC2 604 176 Rept Str Dx Grd 2PSW 15A 125V 5 15R 1 28 CB2 083 432 Circuit Breaker Man Reset 1P 10A 250VAC Frict 1 2930s CB1 089 807 Circuit Breaker Man Reset 1P 2 5A 250VAC Frict 1 eA erus CB1 083432 Circuit Breaker Man Reset 1P 10A 250VAC Frict 1 CIO da ee d eds 212 071 Panel Rear Standard SACO 4212 202 Panel Hear 5 asura a u EIS Chus d e ELA ep a Rr ota AEN 126 026 Label Warning Electric Shock Can Kill Significant EC e ed Et Nameplate Rear Order by Model and Serial Number 582 Nameplate Rear Aux Order by Model and Serial Number 1 175 282 Cover Receptacle Weatherproof Duplex Rept 1 217 480 Label Warning Incorrect Connections 1 cL 215 980 Bushing Strain Relief 709 984
45. 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 user Ref 803 705 A Ref 803 691 C OM 229 409 Page 19 SECTION 5 OPERATION 5 1 Front Panel Controls 1 Power Switch The fan motor is thermostatically controlled and only runs when cooling is needed 2 Voltmeter 3 Ammeter 4 V A Voltage Amperage Adjustment Control 5 Mode Switch The Mode switch setting determines both the process and output On Off control see Sec tion 5 3 For Air Carbon Arc CAC A cutting and goug ing place switch in Stick position For best re Sults place Arc Control in the maximum posi tion 6 Remote 14 Receptacle For remote control make connections to Re mote 14 receptacle In TIG modes and the REMOTE STICK mode remote control is a percent of V A Adjust control setting value selected on V A Adjust is maximum available on remote In ELECTRODE HOT STICK mode the remote control is not used In the MIG mode remote control provides full range of unit output regardless of V A Adjust
46. ng Generators NOTE Engines are warranted separately by the engine manufacturer x 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF models Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard BrandedMig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6Months Batteries 5 90 Days Parts and Labor MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No Labor Spoolmate Spoolguns Canvas Covers Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors relays brushes slip rings or parts that fail due to normal wear 2
47. nties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped from factory THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES MERCHANTABILITY AND FITNESS Within the warranty periods listed below manufacturer will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Manufacturer must be notified in writing within thirty 30 days of such defect or failure at which time manufacturer will provide instructions on the warranty claim procedures to be followed Manufacturer shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to the distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Engine Driven Weldi
48. o 1 204 S m WO Feld 1 lt lt mp KEI a ET Td aS G 0H gt lt lt 9 59 e 908 L i d NOT Feld a hes AZL IYI 443 8 c2u z cou 2 AGL AFIS OL S 0H S 2H LE 1 928 beg gt 7 715009 CL NIA by e v 915008 91 a E ji Tou FIII A GES tee zou ii SIT NOSE 2 I Re 108 gt gt lt lt s 108 5 T J CHINS ZZ 472 SN 5 01 108 gt gt m Umetno i 9 EMINS 92 LIM ao0009000g88 25558 Ell LON FRE RSS LS AA TEM GZ 478 ESS 9 194 5 Z c tq uy iO mers DEBED od snm mpm o n 98 9 g 9 9 9 2 o SERERE con lt lt 1 138 x dE 3 48s Z 7 6 104 gt gt 8 a 2 480WS ZZ LHM e o L 10N 9 104 9 8 9 1 E FIM 18 we L LIH gt gt f sw oz am o ON OM 229 409 Page 27 SECTION 8 PARTS LIST Ref 803 690 H Figure 8 1 Parts Assembly OM 229 409 Page 28 Item Dia Par No Mkgs No Description Quantity Figure 8 1 Parts Assembly rd dnd ie tt dod vs 229541 Wrapper Includes Insulators and Safety Labels 175256 Insulator Side Rh Not Shown 178551 Insulator Side Not Shown ELLA 194 327 Label Warning Genera
49. onctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la Sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger n Ne pas toucher aux pi ces lectriques sous tension e Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la
50. out l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e Encas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements 4 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 229 409 Page
51. pirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 229 409 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et de
52. place READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots 9 Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take ext
53. plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approv
54. ps Includes 1 126 026 Label Warning Electric Shock Can Kill Significant 1 DOVER 2239343 Clip Wire Stdf 40 50 Bndl 156Hole 031 078Thk 2 PLG13 130203 Housing Plug Pins Service Kit RC1 aie une vaan ban P bene d ts PLG14 201665 Housing Plug Pins Service Kit RC2 UN PLG15 115092 Housing Plug Pins Service Kit RC3 PLG20 115093 Housing Plug Pins Service Kit RC6 teste exti was a prd 153 403 Bushing Snap In Nyl 750 Id X 1 000 Mtg Hole Cent 2 2 48 RM1 205 751 Module Power Resistor W Plug 1 SA EE res 217 625 Kit Input Pre Regulator And Inverter Module Includes 1 cusan ARS LA Ai Stee Me casa MOD 1 SKiip 88 HEC A pid Gianni ee EMT i um MOD 2 SKiip 83 EG rere ce l a ad dea d ee MS 212206 Windtunnel Rh 1 Dd ae de Reit on 196 330 Heat Sink Power Module 1 Dee 1754132 be ep Eel OC CENE ERO UR 1 o e PET 228325 Foot Mtg URI ane a aS NSS SI ae BEC eR eb 4 O0 esa ve puta da 176 736 Screw Mtg Foot 4 D
55. put control if present on unit 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 as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Indicates special instructions JW This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly groun
56. r voltage or duty cycle before welding E gt Single Phase Operation The unit is supplied with a 8 AWG power cord The rated output with 8 AWG is 300 amps 32 volts at 4096 duty cycle To 500 achieve 6096 duty cycle 425 change cord to 6 AWG 400 NOTICE Exceeding duty cycle 0 350 can damage unit and void warranty D 300 a THREE PHASE z 250 OPERATION o 6AWG POWER CORD SINGLE PHASE 200 Z 8AWG POWER CORD OPERATION Lu 150 100 10 15 20 25 30 40 50 60 70 80 90 100 DUTY CYCLE 60 Duty Cycle zm 6 Minutes Welding 4 Minutes Resting Overheating 0 Aor V uut NS OR Minutes Reduce Duty Cycle Ref 216 568 A Notes OM 229 409 Page 12 SECTION 4 INSTALLATION 4 1 Dimensions And Weight Hole Layout Dimensions A 11 3 4 in 298 mm T B 1 11 16 in 42 mm C 15 3 4 in 400 mm D 19 3 32in 485 mm E 8 11 16 in 221 mm F 1 17 32 in 39 mm i G 1 4 20 UNC 2B thread Weight 80 Ib 36 3 kg 804 801 A N ERE NE SAA 4 2 Selecting a Location ux 7 A Do not move or operate unit where it could tip Movement 1 Lifting Handles Use handles to lift unit 2 Hand Cart Use cart or similar device to move unit 3 Rating Information Use rating information on rear panel to determine input power n
57. ra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 229 409 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in W
58. rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories 9 Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure
59. re la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat
60. s quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la
61. s gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un res
62. scription Quantity Figure 8 1 Parts Assembly Continued 174 992 Knob Pointer 840 Dia X 250 Id W Spring Clip 21 1 xd dosis 212949 Label Process seen eene eee eee 1 aa 218041 Door W Quick Access Ball Fasteners 1 175 138 BOX LOUVE T tarn an er REA NORD Y RU REG CEA an url art ede 1 aa ew Label Order by Model and Serial Number 1 sut sts Sea 212 207 Windtunnel LA 1 MACHTE E 211503 Insulator Heat Sink 1 vo M rev e ER ARES 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 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 229 409 Page 31 Notes H OF WELDING TECHNOLOGY Start Your Professional 400 trade square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 Notes SOCKET WRENCH SELECTION TABLE Qu SOCKET WRENCH SELEC
63. ter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 229 409 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium
64. uipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les o circuits imprim s gt S N e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent 9 provoquer des blessures 2 f e Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 229 409 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures AJ e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebranc
65. xible cord and cable requirements OM 229 409 Page 16 4 6 Weld Output Receptacles And Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area gt Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding Weld Output Terminals A Turn off power before connecting to weld out ii pn i put terminals 150 200 250 300 350 400 100 ft 30 m or Less A Bo not uss worn dani 45 m 60 m 70m 90m 105 m 120 m aged undersized or poorly spliced cables 10 60 60 100 Duty Duty 10 100 Duty Cycle P Cycle Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 110 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 Output Receptacles 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3
66. y a low sensing voltage approxi 3 mately 15 VDC is present between the electrode and the workpiece prior to the electrode touching the workpiece Consult a Factory Authorized Service Agent for infor mation regarding how to configure the unit for low OCV stick welding operation OM 229 409 Page 22 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance Disconnect power before maintaining gt Maintain more often during severe conditions Ha 3 Months WARNIN A E Replace Repair Or Damaged Or Replace Unreadable Cracked Labels Cables Replace Cracked Torch Body di Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections Blow Out Inside 7 6 2 Blowing Out Inside Of Unit A Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown Ref 803 691 C OM 229 409 Page 23 6 3 Voltmeter Ammeter Help Displays F gt All directions are in reference to the front of the unit All circuitry referred to is lo cated inside the unit 1 Help 1 Display Indicates a malfunction in the primary power circuit If this display is shown contact a Fac tory Authorized Service Agent 2 Help 2 Display Indicates the left side of the unit has over heated T

Miller Electric EXTREME 360 User's Manual

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