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Red-D-Arc EXTREME 360 Specifications

1. 1 A sarang nia 216112 Fastener Panel Receptacle Quick Access 2 Os 0 7 xx 214 749 Capacitor Assy W Plug And Leads Voltage Feedback 1 FE PEPPER 226590 gt Panel Front Standard 22 beh da be Een dene a ia tai DX A ES 1 VOR ix Lach cee dak 231 470 Nut Adapter Encoder Shaft Mtg 375 32 To 500 28 1 T9 ES e uuo 241027 X 0rez Toroidal auicm treo t em e IRE Re E etre CA cR a 1 When ordering a component originally displaying a precautionary label the label should also be ordered Part of 115V Aux Power Option BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 237 881 Page 49 Notes SOCKET WRENCH SELECTION TABLE SOCKET WRENCH SELECTION TABLE U S STANDARD METRIC Specifications Socket or Wrench Size Specifications Socket or Wrench Size U S Diameter Equivalent Bot Nu Diameter Decimal Bot Nu 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 8 mm 3150 in 14 mm 14 mm 3 8 in 3 5 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 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 22 mm 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 1 in 18 mm 7087 in 27 mm 27 mm 3 4 in 50 in 1 1 8 in 1 1 8 in 22 mm 8661 in 32
2. 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 REMEDIES 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 WARRANT Y 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
3. 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 respirateur 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 provoquer des br lures dans les yeux et 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 e Porter un casque de soudage approuv muni de verres filtrants appropri pour pr
4. Inductance influences the arc stiffness bead width and appearance and puddle fluidity in MIG and V Sense Feeder Welding Modes see Sections 7 2 and 7 8 SharpArc optimizes the size and shape of the arc cone bead width and appearance and puddle fluidity in Pulsed MIG Welding Mode see Section 7 4 OM 237 881 Page 11 3 4 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 minutes for unit to cool Reduce amperage or voltage or duty cycle before welding Single Phase Operation The unit is supplied with a 8 AWG power cord The rated output with 8 AWG is 300 amps 32 500 volts at 40 duty cycle To 425 achieve 6096 duty cycle change 400 cord to 6 AWG N a Sap NOTICE Exceeding duty cycle can 300 THREE PHASE damage unit and void warranty 250 OPERATION TM 6AWG POWER CORD SINGLE PHASE 8AWG POWER CORD OPERATION l gt 150 100 10 15 20 25 30 40 50 60 70 80 90 100 7DUTY CYCLE 60 Duty Cycle gt O 6 Minutes Welding 4 Minutes Resting A or V Overheating A ee gt A On Minutes Reduce Duty Cycle Ref 216 568 A OM 237 881 Page 12 SECTION 4 INSTALLATION 4 1 Serial Number And Rating Label Location The serial number and rating information for this product is located on the rear panel Use rating l
5. NN Setup For typical system connections refer to Section 7 1 Rotate Mode Switch to MIG position as shown The preset voltage is shown in the Left Dis play with the Volts Indicator lit Operation While the Volts Indicator is lit under the Left Display the Adjust Control is used to set desired preset voltage E7 The preset voltage can be adjusted re motely at the wire feeder if the feeder has a voltage control This voltage con trol will override the Adjust Control of preset voltage on the welding power source Pressing the Setup Button allows adjust ment of Arc Control Wire Type Gas Type and preset voltage For best results select the appropriate Wire and Gas Type to match the actual wire and gas being used Refer to the MIG Wire and Gas Selection Table for available wires and gases see Section 7 3 Selecting a Wire and Gas Press the Setup Button repeatedly until the Wire Type indicator is lit The active Wire Type will appear in the Left and Right Dis play Rotate Adjust Control to select desired wire Press the Setup Button again so the Gas Type indicator is lit The active Gas Type will appear in the Left and Right Display Rotate Adjust Control to select desired gas 226 611 A Press the Setup Button to confirm the selection The unit will acknowledge a change of wire and gas information by dis playing PROG LOAD momentarily Arc Control Inductance Press the Set
6. 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 4 8 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 A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source In dedicated circuit installations the National Electrical Code NEC allows the receptacle or conductor rating to be less than the rating of the circuit protection device All components of the circuit must be physically compatible See NEC articles 210 21 630 11 and 630 12 Single Phase Input Volt
7. LA CHUTE DE L QUIPEMENT peut provoquer des blessures 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 e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal 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 L3 LES TINCELLES PROJET ES peuvent 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 manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner
8. 1 5 Years Parts 3 Years Labor Original main power rectifiers only to include SCRs diodes and discrete rectifier modules 2 3 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor Transformer Rectifier Power Sources Water Coolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices QCoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors 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 Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HF Units ICE Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers and Electronic Controls Recorders Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches
9. C7 The trim can be adjusted remotely at the wire feeder if the feeder has a volt age control This voltage control will override the Adjust Control of trim on the welding power source Pressing the Setup Button allows adjust ment of Arc Control Wire Type Gas Type and Arc Length C7 For best results select the appropriate Wire and Gas Type to match the actual wire and gas being used Refer to 1 Pulsed MIG Wire and Gas Selection Table for available wires and gases see Section 7 5 Selecting a Wire and Gas Press the Setup Button repeatedly until the Wire Type indicator is lit The active Wire Type will appear in the Left and Right Dis play Rotate Adjust Control to select desired wire Press the Setup Button again so the Gas Type indicator is lit The active Gas Type will appear in the Left and Right Display Rotate Adjust Control to select desired gas Press the Setup Button again to confirm the selection The unit will acknowledge a change of wire and gas information by dis playing PROG LOAD momentarily Arc Control SharpArc Press the Setup Button repeatealy until the Arc Control indicator is lit SHRP appears on the Left Display and the corresponding SharpArc setting appears on the Right Dis play Rotate Adjust Control to select desired SharpArc setting from 0 to 50 default is 25 Adjusting the SharpArc setting changes the welding arc cone Lower settings widen the arc cone increases puddle
10. e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 237 881 Page 5 ll reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e e 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 LES PI CES CHAUDES peuvent provoquer des brulures e Ne pas toucher a mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e 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 LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des 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 Si la 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
11. 16 1 6 AL4X 4000 Series Aluminum ARGN ARGON 10 035 0 9 AL5X 5000 Series 040 1 0 AL5X 5000 Series 3 64 1 2 AL5X 5000 Series 1 16 1 6 AL5X 5000 Series For self shielded FCAW wires use the ARGN CO2 gas selection and set inductance to less than 10 Wire diameter in inches mm Refer to section 5 3 to change displayed units Notes OM 237 881 Page 30 7 4 Pulsed MIG Welding Mode GMAW P Process Manufactured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 5 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 188 6 426 888 Other Patents Pending I REMOTE Le LIFEARC TIG La SCRATCH START gt TIG V SENSE FEEDER ADJUST o C Arc Control Le SETUP 9 10 y A Weld terminals are energized through the remote control in Pulsed MIG welding mode Mode Switch Volts Indicator Left Display Right Display Arc Length Indicator Adjust Control Wire Type Indicator Arc Control Indicator 9 Setup Button 10 Gas Type Indicator Setup CO NOOO WD For typical system connections refer to Section 7 1 Rotate Mode Switch to PULSED MIG posi tion as shown The trim setting is shown in the Left Display with the Arc Length Indicator lit Operation While the Arc Length Indicator is lit under the Left Display the Adjust Control is used to set desired trim setting
12. 237 881 Page 44 SECTION 10 ELECTRICAL DIAGRAM A WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit RC50 A RC50 1 115VAC 67 67 7 RC50 G RCS0 K RC50 J RC50 B RC50 E RC50 C RC50 F RC50 D RC50 H RC50 L RC50 N RC50 M CNE L1 BLA 7 L2 Moto MEDIA SAE REA L3 o r 7 1 GEN VEL Le is 23VAC I2 29 77 BLUE WHT 3 23 115VAC NEUTRAL 42 il 42 CHASSIS GND 42 Ki AN AA A 115V RMT CONT PLG21 RC21 o wo y 24V RMT CONT RC12 RC12 RC12 RC12 RC12 REF IN res1 12 reso REF_OUT 1V 100A REF COM WFS CMD WFS COM CC CV SELECT PCS FRONT PANEL amp DISPLAY RC2 PLG18 Figure 10 1 Circuit Diagram NEGATIVE 40 O L3 PC2 POWER INTERCONNECT RC1 PLG13 RC2 PLG14 RC3 PLG15 CHASSIS iia O o D POSITIVE AROUND L8 AND THRU NOTE TWISTED LEADS MUST BE ROUTED THRU WRAPPED AR a tp O o O O c tc lt 6 20Y o1 o8 gt A H4 BO NEA 3 FETES gt AT g9 cou gt SETE lt L 28 eL AS RN cou gt 2772 lt 1 0N AT ETS 9 08Y es gt HOT Jed lt E S 0Y v cou gt AZI A lt ee 2 628 E cou gt ASI 73947 lt L 23 gt ZU a G O4 J 45008 74 477 o u T gt 215008 91 LHM
13. 7 3 for suggested in ductance setting for the specific wire and gas being used 7 Each Wire and Gas Type combination has independent preset voltage and in ductance settings These settings are preserved when the unit is turned off OM 237 881 Page 35 7 9 V Sense Feeder Welding Mode GMAW P Process a Manufactured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 6 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 189 6 426 888 Other Patents Pending e lt in Li A o a E gini FE STICK SCRATCH p g V SENSE START FEEDER TIG ADJUST i 8 C Arc Control Weld terminals are energized at all times in V Sense Feeder welding mode Mode Switch Volts Indicator Left Display Right Display Arc Length Indicator Adjust Control Wire Type Indicator Arc Control Indicator 9 Setup Button 10 Gas Type Indicator Setup CO N OORA C N For typical system setup connections refer to Section 7 7 Rotate Mode Switch to V SENSE FEEDER position as shown The Left Display toggles between open cir cuit voltage and the trim setting The open circuit voltage is shown while the Volts Indi cator is lit and the trim setting is shown while the Arc Length Indicator is lit Operation While the Arc Length Indicator is lit under the Left Display the Adjust Control is used to set desired trim
14. 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 dali p P brand_warr 2011 01 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 A RC 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 ORIGINAL INSTRUCTIONS PRINTED IN USA 2011 01
15. as manual control Even when Auto is displayed operation will be manual when any other feeder is connected See product literat ure for a list of compatible synergic feeders Pulsed MIG Adjustment This option allows adjusting the Pulsed MIG process in units of Arc Length PULS ARC L or preset voltage PULS VOLT Wire Feed Speed And Wire Diameter Units WFS IPM WFS is displayed in inches per minute Diameter is displayed in inches WFS MPM WFS is displayed in meters per minute Diameter is displayed in millimeters Voltage Reducing Device VRD Mode This option enables ON or disables OFF low open circuit voltage OCV operation in Stick and Scratch Start TIG modes See Section 8 4 for Low OCV Operation When en abled VRD ON is momentarily displayed after the power on front panel LED test 7 If VRD ON is displayed with a dash preceding ON Low OCV Operation is enabled by hardware configuration and cannot be disabled in this menu Panel and Remote Adjustment When the Mode Switch is set to SCRATCH START TIG LIFT ARC TIG or STICK the remote command behavior is configurable SCRATCH START TIG and LIFT ARC TIG default to panel and remote PANL RMT amperage adjust ment but can be configured for panel only PANL ONLY ad justment The default amperage adjustment for STICK is panel only PANL ONLY but can also be configured for panel and remote PANL RMT adjustment All other Mode Switch positions are non configur
16. d Blow Out Inside d 9 2 Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown Blowing Out Unit 2010 01 OM 237 881 Page 41 9 3 Help Displays OM 237 881 Page 42 7 All directions are in reference to the front of the unit All circuitry referred to is lo cated inside the unit Help 1 Display Indicates a malfunction in the primary power circuit If this display is shown contact a Fac tory Authorized Service Agent Help 2 Display Indicates a malfunction in the thermal protec tion circuitry If this display is shown contact a Factory Authorized Service Agent Help 3 Display Indicates the left side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 3 4 Operation will continue when the unit has cooled 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 4 Operation will continue when the unit has cooled Help 6 Display Indicates operation at maximum input cur rent The unit has a maximum allowable input 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 ope
17. fluidity and flat tens the weld bead appearance Higher settings narrow the arc cone re duces puddle fluidity and crowns the weld bead appearance t7 Each Wire and Gas Type combination has independent Arc Length and Shar pArc settings These settings are pre served when the unit is turned off 226 611 A Arc Length Pulsed MIG Manual Control see Section 5 3 Arc length corresponds to the level of ener gy needed to burn off the welding electrode As wire feed speed increases a higher arc length setting is required to burn off the additional wire The arc length setting ap pears in the Left Display when the Arc Length Indicator is lit Arc length can be ad justed from 0 to 100 After the welding output terminals are ener gized but prior to arc initiation the unit dis plays the letter E and a reference wire speed IPM on the Right Display The ref erence wire speed can be used as a start ing point for the wire speed setting at the feeder The wire speed and arc length set ting can then be further adjusted to achieve the desired arc length The Configuration Option Menu see Sec tion 5 1 can be used to change the arc length setting 0 to 100 to average arc volt age Average arc voltage can be used as an alternative method to set the Pulsed MIG welding arc with the same parameters voltage and wire speed as a conventional MIG arc Lower voltage settings corre spond to tighter arc lengths while higher vo
18. lt 2 423A 898 L aed FL DISA ee coy 23 gt gt sag Se 698 SNG A096 1298 gt gt Yum CZ XN G L9 J CHINS ZZ NTI gt 01 198 v sss GS vY 128 lt 2 CHINS 92 LM ZL 19M A A AT 0L IOM JT CMW GE N77 x 9 103 V In UA 6 12M x IDEN PE LEM x 19M ome Eam L LON 3 LEINS EZ MIE 6 198 o ns T 19H a IDUFNS ZZ Lun gt 198 A a 9 194 TUINN 422 MT 1 194 p L 10Y gt OIMYW OZ LAM lt SECONDARY HEATSINK PC1 CONTROL BOARD RC1 PLG1 PRIMARY HEATSINK RC2 PLG2 NV RC8 2 gt RC3 PLG3 RC5 PLG5 RC16 PLG16 A RC6 PLG6 RC10 1 gt IT RC7 PLG7 RC10 2 RC8 PLG8 RC9 PLC9 RC10 PLG10 RC11 PLG11 GAS SOLENOID OPTIONAL L RC11 3 gt RC11 4 gt RC12 PLG12 WHT BLK 254 090 A OM 237 881 Page 45 SECTION 11 PARTS LIST Ref 804 771 D Figure 11 1 Parts Assembly OM 237 881 Page 46 Description Figure 11 1 Parts Assembly Insulator Heat Sink Windtunnel Lh Insulator Screw Bus Bar Diode Resistor Capacitor Kit Diode Fast Recovery Bridge Kit Diode Power Module Thermistor NTC 30K Ohm 9 25 Deg C 18ln Lead Relay Encl 24VDC Spst 35A 300VAC 4Pin Flange Mtg Label Warning Electric Shock Exploding Parts Gasket Inductor Mounting Bushing Snap In Nyl 375 Id X 500 Mtg Hole Inductor Boost Bushi
19. mm 32 mm 7 8 in 875 in 1 5 16 in 1 5 16 in 24 mm 9449 in 36 mm 36 mm 1 in 1 000 in 1 1 2 in 1 1 2 in Warranty Effective January 1 2011 Equipment with a serial number preface of MB or newer This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties 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 OF 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
20. receptacle if required Gas In Connection Optional Gas Cylinder Negative Weld Output Terminal 6 O TIG Torch Workpiece NO NN TOME WA he A 804 841 B OM 237 881 Page 24 6 2 Scratch Start TIG Welding Mode GTAW Process 17 Manufactured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 6 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 189 6 426 888 Other Patents Penal e REMOTE LIFT ARC na IF T STICK SCRATCH 4 P V SENSE START A FEEDER TIG MILLER ELES RIG MFG CO APPLETON WI ADJUST C Arc Control N Wire Type O Gas Type A Weld terminals are energized at all O oa Bb C N times in Scratch Start TIG welding mode Mode Switch Volts Indicator Left Display Right Display Amps Indicator Adjust Control Setup For typical system connections refer to Section 6 1 Rotate Mode Switch to SCRATCH START TIG position as shown The open circuit voltage is shown in the Left Display with the Volts Indicator lit Preset amperage is shown in the Right Display with the Amps Indicator lit 226 611 A Operation The Adjust Control is used to set desired preset amperage 7 If a remote control is used for amper age adjustment the adjustment will function as a percentage of the preset amperage 7 For best results gently scratch the tungsten electrode to the work to
21. setting The Left Display toggling momentarily pauses while the trim setting is ad justed Pressing the Setup Button allows adjust OM 237 881 Page 36 ment of Arc Control Wire Type Gas Type and Arc Length C7 For best results select the appropriate Wire and Gas Type to match the actual wire and gas being used Refer to Pulsed MIG Wire and Gas Selec tion Table for available wires and gases see Section 7 5 Selecting a Wire and Gas Press the Setup Button repeatedly until the Wire Type indicator is lit The active Wire Type will appear in the Left and Right Dis play Rotate Adjust Control to select desired wire Press the Setup Button again so the Gas Type indicator is lit The active Gas Type will appear in the Left and Right Display Rotate Adjust Control to select desired gas Press the Setup Button again to confirm the selection The unit will acknowledge a change of wire and gas information by dis playing PROG LOAD momentarily Arc Control SharpArc Press the Setup Button repeatedly until the Arc Control indicator is lit SHRP appears on the Left Display and the corresponding SharpArc setting appears on the Right Dis play Rotate Adjust Control to select desired SharpArc setting from 0 to 50 default is 25 Adjusting the SharpArc setting changes the welding arc cone Lower settings widen the arc cone increases puddle fluidity and flat tens the weld bead appearance 226 611 A Higher
22. toute sub stance inflammable P 4 Q S ex LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s 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 antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 237 881 Page 7 Les PI CES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage GO Les PI CES MOBILES peuvent causer des blessures e S abstenirde toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique j LIRE LES INSTRUCTIONS e lire et appliqu
23. 9 59 vc a o DR D cO 37 8 1 Typical Connection For SMAW And CAC A Process 37 8 2 CC Welding Mode SMAW CAC A Process 38 8 3 Stick Welding Mode SMAW CAC A Process 39 8 4 Optional Low Open Circuit Voltage OCV Welding Modes 40 SECTION 9 MAINTENANCE amp TROUBLESHOOTING 41 9 1 doutineMaintenarlee zs hosce wel erem e etos uet ahis materi das 41 9 2 Blowing Qut Inside Of Unit 52 sre era aa ee eor na 41 9 9 Hel ISP Saori dr Dr eO ner bara diete eue leaders 42 9 4 JroubleshOoOlllg ss dure EE OE reete eor basa aie mite deuda adita andas 43 SECTION 10 ELECTRICAL DIAGRAM soriana errar DRE EP DRE S RE 44 SECTION TI PAHIS LIST sua anidar ara dia 46 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2011 01 A Protect yourself and others from injury read and follow these precautions 1 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
24. A OPERATION 8 1 Typical Connection For SMAW And CAC A Process Turn off power before mak ing connections 1 Electrode Holder Carbon Arc For CAC A process connect car bon arc cutting torch to to positive weld output terminal 2 Electrode Holder 3 Positive Weld Output Terminal 4 Remote 14 Receptacle Connect desired remote control to remote 14 receptacle as required 5 Compressed Air LIne 6 Negative Weld Output Terminal 7 Workpiece Ref 804 842 B OM 237 881 Page 37 8 2 CC Welding Mode SMAW CAC A Process 2 3 4 5 a Manufactured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 6 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 189 6 426 888 Other Patents Pending C ol O 7 OUTPUT ON A ADJUST 6 C Arc Control C Wire Type LIFT ARC O mae pe ae H a E STICK a SCRATCH amp V SENSE START gt FEEDER n TIG REMOTE SETUP 1 7 226 611 A A Weld terminals are energized through the remote control in CC welding mode Mode Switch Left Display Right Display Amps Indicator Adjust Control Arc Control Indicator Setup Button Setup NO of ND For typical system connections refer to Section 8 1 Rotate Mode Switch to CC position as shown The preset amperage is shown in the Right Display with the Amps Indicator lit Operation While the Am
25. ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e Toreduce 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 lf 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 OM 237 881 Page 3 1 4 California Proposition 65 Warnings 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 A 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 1 5 Principal Safety Standards Safety in Welding Cutting and Al
26. Display toggling momentarily pauses while the preset voltage is ad justed Pressing the Setup Button allows adjust ment of Arc Control Wire Type Gas Type and preset voltage EF For best results select the appropriate Wire and Gas Type to match the actual wire and gas being used Refer to MIG Wire and Gas Selection Table for available wires and gases see Section 7 3 Selecting a Wire and Gas Press the Setup Button repeatedly until the Wire Type indicator is lit The active Wire Type will appear in the Left and Right Dis play Rotate Adjust Control to select desired wire Press the Setup Button again so the Gas Type indicator is lit The active Gas Type will appear in the Left and Right Display 226 611 A Rotate Adjust Control to select desired gas Press the Setup Button again to confirm the selection The unit will acknowledge a change of wire and gas information by dis playing PROG LOAD momentarily Arc Control Inductance Press the Setup Button repeatealy until the Arc Control indicator is lit INDU appears on the Left Display and the corresponding in ductance setting appears on the Right Dis play Rotate Adjust Control to select desired in ductance setting from 0 to 100 Use lower inductance settings to stiffen the arc and re duce puddle fluidity Use higher inductance settings to soften the arc and increase puddle fluidity Refer to the MIG Wire and Gas Selection Table see Section
27. E Indique des instructions sp cifiques 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 dans l ordre indiqu 1 un poste souder DC tension constante 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 CFH 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre 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 Eneffectuant 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
28. E 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 Compressed 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 this is not possible tightly cover them with approved covers e Protect compressed gas cylinders from excessive heat mechani Do not weld where flying sparks can strike flammable material cal shocks physical damage slag open flames sparks and arcs Protect arder flvi ks add hotmeral e Install cylinders in an upright position by securing to a stationary TOM er eN EL a CIE ete de i support or cylinder rack to prevent falling or tipping Be alert that welding sparks and hot materials from welding can e Keep cylinders away from any welding or other electrical circuits easily go through small cracks and openings to adjacent areas e Never drape a welding torch over a gas cylinder Watch for fire and keep a fire extinguisher nearby e Never allow a welding electrode to touch any cylinder Be aware that welding on a ceiling floor bulkhead or partition can e Never weld on a pressurized cylinder explosion will result cause fire on the hidden side e Use only correct compressed gas cylinders regulators hoses e Do not weld on closed containers such as tanks drums or pipes and fitting
29. No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 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
30. OM 237 881J 2011 09 f Processes A MAS Multiprocess Welding A l V VO y s Description RED D ARC e Welderentals E EJ ua E 1 800 245 3660 EXIREME 360 MAP Auto Line OWNER S MANUAL File MULTIPROCESS Ln TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 2 1 3 1 4 1 5 1 6 Symbol 5396 2315 outdo a A Sn tea an en Seas nt IST Arc Weldio Hazards rica daa dada Additional Symbols For Installation Operation And Maintenance California Proposition 65 WAatrrltigS s ac ic a oa A ter Meee oe ea en Principal Safety Standards 5 dos ade ox e choc ea eo pac ib do te em i diede a bs EME HORNO EE SL SRE ii que ue mcs eec ad Meus FUR que IM LM E EE outs cd SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 2 2 2 3 2 4 2 5 2 6 SVIMDOIES WUNSES 4s s sana eene duos operae rl atat avit dau seine isis aen Dangers relatifs au soudage l arc 80 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Proposition californienne 65 Avertissements Principales normes de s curit 2 Informations relatives aux GEM s iure ant tly oP ne Ment alte te S og ed p aed ane tee e uns
31. SECTION 3 INTRODUCTION oie cca ol uk ox Ex ege WERE wie ducateur 3 1 3 2 3 3 3 4 SPECIICANONS xd Sarees SS cad ot ee cera s pup ee ne nec Features And Benel 4 42 ris A pee ies int ie de x3 AGC COMMONS e os oats esl aie ot anata btn nas eee awd eee ete auae aes Duty CycleAnd Overeating rra dd di a ada SECTION 4 INSTALLATION sus cdas aa ER ds ada a A a da ee ee ee 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 Serial Number And Rating Label Location Dimensions ANG WEA ss asap x EG RE CEA bebe ana tended nko si ee ab der a decla s aco Selecting LOCO Cos ears ete oa Sen st PNR IVe E Va adhi aera da ad Weld Output Receptacles And Selecting Cable Sizes Remote 14 Receptacle Information ew sut uc careo cac ko ere bb aeter dus Optional 115 Volts AC Duplex Receptacle And Supplementary Protectors Optional Gas Valve Operation And Shielding Gas Connection Electrical Service Gude Jkr gett Led hit Ges so dx ys esc Fa Ks Ne due se gu us Connecting 1 Phase Input Power 4 LS 4 10 Connecting 3 Phase Input Power 4 4 2 SECTION 5 GENERAL OPERATION ii Siew asin Ge wee hata ea Sea ee eee ea ee aa 5 1 5 2 9 3 Frontal did A Mode SWIICh SCHINGS usa a dano Contiguration ODUOD MERLIN SECTION 6 GTAW OPERATION ins a a
32. a a ia 6 1 6 2 6 3 6 4 Typical Connection For GTAW Process Scratch Start TIG Welding Mode GTAW Process Lift Arc TIG Welding Mode GTAW Process TIG Welding Mode GTAW Process a d RE ar Ra Een x RE IAE SERIA eee tere Y rt SECTION 7 GMAW GMAW P FCAW OPERATION 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 Typical Connection For Remote Control Feeder GMAW GMAW P FCAW Process MIG Welding Mode GMAW FCAW Process MIG Wire and Gas Selection Table 2 Pulsed MIG Welding Mode GMAW P Process Pulsed MIG Wire and Gas Selection Table Remote Process SIC arar dE aU dae aes Ne d Typical Connection For Voltage Sensing Feeder GMAW GMAW P FCAW Process V Sense Feeder Welding Mode GMAW FCAW Process V Sense Feeder Welding Mode GMAW P Process OMOON O1 O1 ATK HP AO NO N NP PO Po NM HH H HH HSH HH AH SH BS o o M do lc o Bb BD DOAN OO O1 O1 BB CO CO CO D TABLE OF CONTENTS SECTIONS SMAW GAC A OPERATION 2 5 5x221 0 9 9 999 04
33. a piece aussi pres que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir 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 237 881 Page 9 OM 237 881 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 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 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 4 for Duty Cycle Rating 3 2 Features And Benefits Auto Line Power Management Technology is circuitry that automatically adapts the power source to the primary voltage being applied see Sections 4 9 and 4 10 LVC Line Voltage Compensation is circuitry that keeps the power source output constant r
34. abel to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 4 2 Dimensions And Weight Hole Layout Dimensions A 11 3 Ain 298 mm B 1 11 16 in 42 mm C 15 3 4 in 400 mm D 19 3 32 in 485 mm E 8 11 16 in 221 mm F 1 17 32 in 39 mm 804 801 A G 1 4 20 UNC 2B thread Weight 80 Ib 36 3 kg 93 5 Ib 42 4 kg w optional 115 VAC 4 3 Selecting a Location 1 Lifting Handles Use handles to lift unit 2 Hand Cart Use cart or similar device to move unit Do not move or operate unit 3 Line Disconnect Device where it could tip Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Location XMT Location 1 OM 237 881 Page 13 4 4 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 30 m 100 ft from the workpiece the total cable length in the weld circuit is 60 m 2 cables x 30 m Use the 60 m 200 ft column to determine cable Size Weld Output Terminals Turn off power be fore connecting to weld output termi nals A Do not use worn damaged under size
35. able and allow both panel and re mote PANL RMT adjustment 7 Panel adjustment is made using the Adjust Control on the front panel Remote adjustment is made using a re mote control device connected to the Remote 14 Recep tacle OM 237 881 Page 23 5 3 Configuration Option Menu Continued Revision Information This option identifies the unit s weld library INFO LIB and firm ware revision INFO REV Press the Setup Button while the unit is displaying INFO LIB to identify the unit s weld library Press the Setup Button while the unit is displaying INFO REV to identify the unit s firmware revision Pressing the Setup Button while the unit is displaying INFO NO will move to the next configuration option Exit Configuration Option Menu Press the Setup Button while the unit is displaying EXIT NO to return to the first configuration option Press the Setup Button while the unit is displaying EXIT YES to exit the Configuration Option Menu Er The Configuration Option Menu can be exited at any time by turning the unit off Only if the unit is turned off after EXIT NO is displayed will configuration option changes be saved SECTION 6 GTAW OPERATION 6 1 Typical Connection For GTAW Process Turn off power before mak ing connections Foot Control 2 Gas Out Connection Optional LA P OD Positive Weld Output AMD Terminal 4 Remote 14 Receptacle Connect desired remote control to Remote 14
36. adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure 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 STATIC ESD can damage PC boards J e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 em MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure 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 5 MOVING PARTS can injure e Keep away
37. age 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 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 Max Recommended Input Conductor Length In Feet Meters 22 S 2 rs o Min Grounding Conductor Size In AWG Kemil 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 Max Recommended Input Conductor Length In Feet Meters eh S ES s a Min Grounding Conductor Size In AWG Kcmil 4 10 10 12 14 14 Reference 2011 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 15 B 16 If a flexible cord or cable is used minimum conduc
38. an amperage adjustment the adjustment will func tion as a percentage of the preset am perage 7 For best results gently scratch the tungsten electrode to the work to initi ate an arc To minimize arc flare at the end of the weld pull back the electrode quickly to extinguish the arc OM 237 881 Page 27 SECTION 7 GMAW GMAW P FCAW OPERATION 7 1 Typical Connection For Remote Control Feeder GMAW GMAW P FCAW Process A Turn off power before making connections Remote 14 Receptacle Positive Weld Output Terminal Negative Weld Output Terminal Ground Cable to Workpiece OM 237 881 Page 28 Workpiece Gun Wire Feeder Gas Hose Gas Cylinder 804 938 A Use of shielding gas is dependant on Wire Type E The connection diagram illustrates DCEP reverse polarity suitable for all wires except self shielded FCAW The majority of self shielded FCAW wires require DCEN straight polarity 7 2 MIG Welding Mode GMAW FCAW Process M E O gt REMOTE N Li fu UT a LIFFARC TIG 4 SCRATCH START TIG gr V SENSE FEEDER ADJUST C Arc Control Wire Type Gas Type gt Weld terminals are energized through the remote control in MIG welding mode Mode Switch Volts Indicator Left Display Right Display Adjust Control Wire Type Indicator Arc Control Indicator Setup Button Gas Type Indicator ON On i
39. ate Rear Order by Model and Serial Number 1 Told PR ahh 5 Ske Sh ds da indi Nameplate Rear Aux Order by Model and Serial Number 1 PEE RET 217 297 Cover Receptacle Weatherproof Duplex Rept 1 TC TD 217 480 Label Warning Incorrect Connections 1 Sup oo dde dc ARTE 215 980 Bushing Strain Relief 709 984 Id X1 375 Mtg Hole 1 iun OD Sidi 219 487 Cable Power 12 Ft 8Ga 4C Non Stripped End 1 CEN CT IEEE 234 126 Nut Conduit 1 000 Npt Knurled 1 Kat eae A 211 109 XFMR Control 665V 336Va Syn Aux Pwr 1 TOO ust 2 211 968 XFMR Control Toroidal 665 VAC Pri 1536 Va 60 Hz 1 HN ei e 212 947 Plate Mtg Toroid XFMR 24 5245 465 Ue ime NE ae d Vende otis Hts R PUR 218 018 Inductor Pre Regulator 1 MAO ora A 218 566 Gasket Inductor Mounting 1 ess GTI sida 196 231 lt XMER Current Sensing 20071 a cidad ACE 1 ee eee O15 iis 196 143 Capacitor Polyp Met Film 16 Uf 400 VAC 1096 1 D OPE 216 117 Bracket Mtg Capacitor Series 1 DIE Ys RIZ teeta 199 798 Thermistor Ntc 30K Ohm 25 Deg C 18in Lead 1 rd D uias POS ss 225 442 Circuit Card Assy Interconnect W Label amp C
40. c e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection rom WELDING can cause fire or explosion E 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If 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 E BUILDUP OF GAS can injure or kill e Shut off compressed gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e 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 NOIS
41. c du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ues 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 Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e Sisoler 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 e 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 Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la 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
42. c une housse 2 Ne pas se tenir au milieu des cables de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 t l phone 212 642 4900 site Internet www ansi 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 Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du materiel du circuit de soudage 5 Connecter la pince sur l
43. ceptacle and Remote 14 recep tacle see Section 4 5 2 Supplementary Protector CB1 3 Supplementary Protector 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 supplementary pro tector 803 691 C OM 237 881 Page 15 4 7 Optional Gas Valve Operation And Shielding Gas Connection OM 237 881 Page 16 1 e 20 SY gt Obtain gas cylinder and chain to running gear wall or other station ary support so cylinder cannot fall and break off valve 1 Cylinder 2 HRegulator Flowmeter Install so face is vertical 3 Gas Hose Connection Fitting has 5 8 18 right hand threads Obtain and install gas hose 4 Gas In Fitting 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 mote contactor off if no current was detected Lift Arc TIG
44. d or poorly spliced cables Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150ft 200ft 250ft 300 ft 350 ft 400 ft 100 ft 30 m or Less 45m 60m 70m 90m 105 m 120 m 10 60 60 100 Welding Duty Duty 10 100 Duty Cycle Amperes Cycle Cycle AWG mm AWG mm AWG mm 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2x2 0 2x2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 70 2x70 2x2 0 2x3 0 2x3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 70 2x95 2x95 4 0 2x2 0 2x3 0 2x3 0 2x4 0 350 1 0 60 2 0 70 3 0 95 429 2x70 2x95 2x95 2x120 4 0 2x2 0 2x3 0 2x4 0 2x4 0 400 1 0 60 2 0 70 3 0 95 429 2x70 2x95 2x120 2x120 2x2 0 2x3 0 2x4 0 3x3 0 3x3 0 CHRUPRECEPERSS 500 2 0 70 3 0 95 4 0 120 2 70 2x95 2x120 3x95 3x95 600 2x2 0 2x3 0 2x4 0 3x3 0 3x4 0 3x4 0 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 2 mm for metric use 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 o
45. d NFPA 51B and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e 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 e 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 e Do not weld on coated metals such as galvanized lead or cadmium 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 e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the ar
46. d un respirateur d adduction d air homologu Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage 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 Les bouteilles de gaz comprim contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution 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 Ne jamais plac
47. 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 gt Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent OM 237 881 Page 8 des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apres utilisation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A 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 Safe Practices for the Preparation of Containers and Piping for Welding and Cutting 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 Q
48. droit l o des tincelles peuvent tomber sur des substances inflammables e 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 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 pantal
49. e ADS 182918 Transducer Current 400A Module Supply V 15V 1 kt Eee POS sz 242 725 Circuit Card Assy Front Panel amp Display W Program 1 PET PLG18 131 204 Housing Plug Pins Service Kit RC2 d edm RA RC50 210233 Rept W Pins Service Kit d re PLO21 2120988 23 Pl g W bGadS omita ada Y DO RC21 167640 Housing Plug Pins Service Kit 1 EET DIET 230943 Enclosure Connector DB 9 1 OO cnrs 230 944 Cover Enclosure Connector DB 9 1 Ole ST sss 244 920 Switch Tgl 3Pst 40A 600VAC Scr Term Wide Tgl 1 URTE OA SE buta audi 176 226 Insulator Switch Power 02 1 152199 uita FM1 196 313 Fan Muffin 115V 50 60Hz 3000 RPM 6 378 Mig Holes 1 TT ERA PLG16 181054 Housing Plug Pins Service Kit 1 TTE RC16 135635 Housing Plug Pins Service Kit 1 When ordering a component originally displaying a precautionary label the label should also be ordered Part of 115V Aux Power Option BE SURE TO PROVIDE MODEL AND SEHIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 237 881 Page 48 Item Dia Part NO Mkgs NO Description Quantity Figure 11 1 Parts Assembly Co
50. e de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables 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 En cas 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 A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconna t 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 gt Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l Etat
51. ed for the welding process e f AC output is required use remote output control if present on unit e 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 e 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 e Properly install and ground this equipment according to its Owner s Manual and national state and local codes C7 Indicates special instructions e a D A 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 e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to
52. egardless of input pow er fluctuation Wind Tunnel Technology circulates air over components that require cooling not over electronic circuitry which reduces contaminants and improves reliability in harsh welding environments Fan On Demand cooling system operates only when needed reducing noise energy use and the amount of con taminants pulled through the machine Thermal Overload Protection automatically shuts down the unit only when necessary to prevent damage to internal components if the duty cycle is exceeded or air flow and cooling are restricted see Section 3 4 Auto Remote Sense enables the unit to automatically sense the connection of a remote control Operation of the remote control is dependent on the Mode Switch Setting see Section 5 2 Lift Arc TIG starts provide a contamination free weld without the use of high frequency in the Lift Arc TIG Welding Mode see Section 6 3 Synergic Pulsed MIG Operation allows single knob control of the arc As wirefeed speed is increased or decreased the pulse parameters increase or decrease matching the power output to the wire speed see Section 5 3 3 3 Arc Controls DIG control allows the arc characteristics soft versus stiff to be changed for specific applications and electrodes in CC and Stick Welding Modes see Sections 8 2 and 8 3 Programmable Hot Start allows the start amperage and time to be changed for CC and Stick Welding Modes see Sections 8 2 and 8 3
53. er les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur E e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FREQUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs 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 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 SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risqu
54. er une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz comprim 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 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 mentaires en relation avec l installation le fonctionnement et la maintenance y Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service
55. eration The Adjust Control is used to set desired preset amperage 7 If a remote control is used for amper age adjustment the adjustment will function as a percentage of the preset amperage F For best results firmly touch the tung sten electrode to the workpiece at the weld start point Hold electrode to workpiece for 1 2 seconds and lift electrode An arc will form when the electrode is lifted To minimize arc flare at the end of the weld pull back the electrode quickly to extinguish the arc 6 4 TIG Welding Mode GTAW Process a Manufactured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 6 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 189 6 426 888 Other Patents Pending O Gl 4 5 C Arc Control C Wire Type O Gas Type LIFFARCm TIG SS O SCRATCH 4 V SENSE m START gt FEEDER TIG FE STICK REMOTE 226 611 A A Weld terminals are energized aor N through the remote control in TIG welding mode Mode Switch Left Display Right Display Amps Indicator Adjust Control Setup For typical system connections refer to Section 6 1 Rotate Mode Switch to TIG position as shown The preset amperage is shown in the Right Display with the Amps Indicator lit Operation The Adjust Control is used to set desired preset amperage A remote control is required to turn on the weld output E If the remote control has
56. et 1P 10A 250VAC Frict Panel Rear Item Dia Part No Mkgs No TE Me ees EE 237 879 cee a ii as 175 256 A A 178 551 TTE 134 327 M e Te 138 442 A 195 585 AN 135 483 PIE c EE ETE 225 097 Taper 211 503 wq E 212 207 EET 196 355 oL 199 840 11 R3 C4 233 052 12 SRT s 201 530 19 32 DT D2 201 531 Are ETT ss 199 798 AD CR1 198 549 zio Se eee mte e 227 127 PES EN 227 746 DO s SAR mee AUS 010 546 Cie 4 222 218 020 x quat mE dum die m 179 276 PR E seal mck oh 170 647 22 iex es ES 212 150 Ada p 212 132 p E A 212 091 To Si nie 083 147 26 POT uus 242 812 AO PC1 242 341 ia e Ea 216 113 DE PLG1 115 091 NCC ERR PLG2 201 665 Pcr PLG3 131 056 anida PLG5 131 204 ee ene PLG7 131 054 A PLG8 131 054 ET PLG9 115 093 ee er ee PLG10 115 094 RE PLG11 115 094 mn PLG12 115 092 mor 212072 28 C12 13 219930 DE RC2 604 176 29 CB2 083 432 ud o sa CB weeks 089 807 E O ES CB1 083432 PS MUN 212 071 le E 4212202 Toc MERE RR 126 026 Label Warning Electric Shock Can Kill Significant When ordering a component originally displaying a precautionary label the label should also be ordered Part of 115V Aux Power Option BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 237 881 Page 47 No Mkgs No Description Quantity Figure 11 1 Parts Assembly Continued RS CR Hick tah TE Namepl
57. 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 entrainer 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 e 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 utiliser qu un mat 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 facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e lsoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique
58. from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place se e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 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 Theuseris 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
59. ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level e Keep all panels and covers securely in place e Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exis
60. hot start amperage Higher numbers result in higher start am perage Press the Setup button again so HOT T ap pears on the Left Display HOT T adjusts the Hot Start Time to Adaptive Hot Start AUTO or from Min 1 to Max 50 Adapt ive Hot Start AUTO automatically chooses a default Time The Min 1 setting results in no hot start time Higher numbers result in longer start time Press the Setup Button to return to adjust ment of preset amperage Use this mode for Air Carbon Arc CAC A cutting and gouging For best results adjust dig setting to maximum 8 3 Stick Welding Mode SMAW CAC A Process 2 3 4 5 6 3 Manufactured Under the Era Eit Ond 5 902 150 6 239 407 8 266 207 6 629 046 Oiher Patents Pending 12 0 85 e G os OUTPUT ON V A ADJUST 7 C Arc Control N C Wire Type C Gas Type LIFT ARCim E stick TIG O SCRATCH 4 V SENSE START FEEDER E 4 TIG REMOTE SETUP Le 1 8 226 611 A A Weld terminals are energized at all times in Stick welding mode Mode Switch Volts Indicator Left Display Right Display Amps Indicator Adjust Control Arc Control Indicator Setup Button Setup CONDO OF D For typical system connections refer to Section 8 1 Rotate Mode Switch to STICK position as shown The open circuit voltage is shown in the Left Display with the Volts Indicator lit and the preset amperage i
61. icator Arc Control Indicator 804 772 A 226 611 A Remote PC Interface Setup Button Gas Type Indicator Mode Switch Power Switch Weld Output Terminal Optional Gas Valve Knockout Weld Output Terminal 12 13 14 15 16 17 18 19 5 2 Mode Switch Settings Switch Position Process Output Control Panel Adjust Remote Adjust Scratch Start TIG Electrode Hot Panel Amps Lift Arc TIG Electrode Hot Panel Amps Pulsed MIG Remote 14 Arc Length 0 100 Arc Length 0 100 See Configuration Option Menu see Section 5 3 For adjustment alternatives Notes OM 237 881 Page 21 5 3 Configuration Option Menu Manufactured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 6 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 189 6 426 888 Other Patents Panding O Gl PULSED pi MIG ue Je Li STICK SCRATCH 4 V SENSE START gt A FEEDER TIG ELECTRODE NOT MILLER ELECTRIC MFG CO APPLETON WI a ADJUST C Arc Control O Wire Type C Gas Type O Mode Switch Remote 14 Receptacle Left Display Right Display Adjustment Control Remote PC Interface Setup Button OM 237 881 Page 22 Setup The Configuration Option Menu provides a means to customize some machine features for desired operation To enter the Configuration Option Menu hold the Setup Button down during power up while the unit is display
62. ing 8888 on the Left and 226 611 A Right Displays SET UP will be displayed momentarily Configuration options are displayed in the Left Display Settings are displayed in the Right Display Settings can be changed by turning the Adjust Control If a setting does not change when the Adjust Control is turned the option is not configurable Pressing the Setup Button moves to the next configuration option 5 3 Configuration Option Menu Continued V Sense Feeder Weld Process ICE N This option enables MIG V SEN MIG or Pulsed MIG v LL V SEN PULS when the Mode Switch is in the VSENSE FEEDER position See Section 7 2 for MIG operation or Sec tion 7 4 for Pulsed MIG operation Pulsed MIG Manual Auto Control This option sets the PULSED MIG control as manual PULS MAN or Auto PULS AUTO operation When set to manual operation the arc length setting on power source and wire speed setting on wirefeeder need to be adjusted indepen dently to achieve the desired arc length When set to Auto op eration once arc length is determined it is not necessary to change the arc length value with changes in wirefeed speed The EXTREME 360 MAP and synergic feeders allow single knob control of the arc As wirefeed speed is increased or de creased the pulse parameters increase or decrease match ing the power output to the wire speed EF Auto Operation will only work with synergic wirefeeders All other wirefeeders will only operate
63. initi ate an arc To minimize arc flare at the end of the weld pull back the electrode quickly to extinguish the arc OM 237 881 Page 25 6 3 Lift Arc TIG Welding Mode GTAW Process T Manulaclured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 6 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 189 6 426 888 Iher Palenis Pending e REMOTE LIFTARC na Ie CL stick SCRATCH 9 V SENSE START gt FEEDER TIG MILLER ELE7TRIC MFG CO APPLETON WI ADJUST C Arc Control C Wire Type C Gas Type 226 611 A Weld terminals are energized at all times in Lift Arc TIG welding mode 1 Mode Switch Volts Indicator Left Display Right Display Amps Indicator Adjust Control Workpiece o N O Oo A WO WD Tungsten Electrode OM 237 881 Page 26 Setup For typical system connections refer to Section 6 1 Rotate Mode Switch to LIFT ARC TIG posi tion as shown The open circuit voltage is shown in the Left Display with the Volts Indicator lit Pre set amperage is shown in the Right Display with the Amps Indicator lit Normal open circuit voltage is not present before the electrode touches the work piece instead a low sensing voltage is present The sensing voltage allows the electrode to touch the workpiece without overheating sticking or getting contami nated Do NOT Strike Like A Match Op
64. lied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access re
65. lips Includes 1 EE PIE 126 026 Label Warning Electric Shock Can Kill Significant 1 E 223 343 Clip Wire Stdf 40 50 Bndl 156Hole 031 078Thk 2 ET TRE E re ee 153 403 Bushing Snap In Nyl 750 Id X 1 000 Mtg Hole Cent 2 iiu MO dub bd dw hou 217625 Kit Input Pre Regulator And Inverter Module Includes 1 PCT MOD 1 SKIIb 83 HEC uti tii CER 1 E EENT EEE EE twat ena MOD 2 SKID SS BO Lun dra I p PLG13 130 203 Housing Plug Pins Service Kit RCA d D PETENS PLG14 201665 Housing Plug Pins Service Kit RC2 d as s PLG15 115092 Housing Plug Pins Service Kit RC3 d EO PLG20 115093 Housing Plug Pins Service Kit RC6 d sd si ss RM1 205 751 Module Power Resistor W Plug 1 WW ee dr 212200 WINNER 1 ES Mt pale nt eee du 196 330 Heat Sink Power Module 2 1 Um prc pM CA A iab deed haud aetate he te uo Dn i e ME 1 en PAS t Ead 153 178 Label Warning Exploding Parts Can Serious Injury 1 PIE PE 170 700 90e Ww Mig FOOL s track anes a SR RE in aes SETTE RS 4 RME S DROP OU 229929 ROOL MIO DUBIE o ota eb eae dia ita ee aie 4 E aud eive ded Bes 212 074 Bus Bar Output 4 455 4 9 depu n doas idc at nbd ba adds 1 MES acn
66. llow 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 8 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position Tools Needed m inputi 2011 03 803 766 C OM 237 881 Page 19 SECTION 5 GENERAL OPERATION 9 1 Front Panel 4 6 9 FC M iila MILLER ELECTRIC MFG CO APPLETON WI 6 002103 6 115 273 6 193 548 6 230 407 6 266 257 6 625 046 2 Fatema Panning OUTPUT ON V s A C PA Y ADJUST 3 5 7 l mic PULSED s F MiG ds eon lt lt n Arc Control Sy D JUL SI C Wire Type LIFT ARCru 9 cen DRE is TIG La CL STICK E O SCRATCH V SENSE START gt FEEDER IT TIG 14 E E 1 P cas OUT OPTIONAL 16 E Weld process operation sections de o Ci BR ND scribe functionality of the identified items Remote 14 Receptacle Output ON Indicator Light Volts Indicator Left Display Arc Length Indicator Right Display OM 237 881 Page 20 C7 The meters display the actual weld output O0 N values after arc initiation and remains dis played for approximately three seconds after the arc is broken Amps Indicator Setup Indicator Adjust Control Wire Type Ind
67. ltage settings correspond to longer arc lengths If the voltage mode is selected the average voltage preset will be displayed on the Left Display with the Volts Indicator lit Arc Length Pulsed MIG Auto Control see Section 5 3 In Auto operation the arc length setting is 0 100 The programs have been developed at 50 arc length setting Increasing or de creasing the arc length setting from 50 will change the arc length It is not necessary to change the arc length value when changing wire feed speed settings OM 237 881 Page 31 7 5 Pulsed MIG Wire and Gas Selection Table WIRE TYPES GAS TYPES Sied 035 0 9 STL ARGN CO2 ARGON CARBON DIOXIDE dir 045 1 2 STL ARGN OXY ARGON OXYGEN 045 1 2 MCOR Metal Core 052 1 4 MCOR ARGN CO2 ARGON CARBON DIOXIDE TRI MIX TRI GAS MIXTURE Stainless Steel we o eel ARGN OXY ARGON OXYGEN ARGN CO2 ARGON CARBON DIOXIDE 035 0 9 AL4X 4000 Series 040 1 0 ALAX 4000 Series ARGN ARGON 3 64 1 2 AL4X 4000 Series 1 16 1 6 AL4X 4000 Series Aluminum 035 0 9 AL5X 5000 Series 040 1 0 AL5X 5000 Series ARGN ARGON 3 64 1 2 AL5X 5000 Series HE AR25 HELIUM ARGON 1 16 1 6 AL5X 5000 Series Mies 035 0 9 NI ARGN HE ARGON HELIUM M 045 1 2 NI ARGN ARGON Copper Nickel ve o GUN HE ARGN HELIUM ARGON Silicon Bronze ae Ho SEE ARGN ARGON Wire diameter in inches mm Refer to section 5 3 to change displayed unit
68. n 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 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 Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement 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 inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage ave
69. ng Snap In Nyl 1 000 Id X 1 375 Mtg Hole Cent Bushing Snap In Nyl 1 312 Id X 1 500 Mtg Hole Inductor Output XFMR HF Litz Litz W Boost Inductor Input Housing Plug Pins Housing Plug Pins Housing Plug Pins Housing Plug Pins Housing Plug Pins Housing Plug Pins Service Kit RC12 Bracket Mtg Capacitor PC Board Kit Capacitor Elctlt Replacement Rept Str Dx Grd 2P3W 15A 125V 5 15R Wrapper Includes Insulators and Safety Labels Insulator Side Rh Not Shown Insulator Side Not Shown Label Warning General Precautionary Static amp Wire Feed Label Caution Falling Equip Can Cause Injury Handle Rubberized Carrying Label Important Remove These Two Handle Screws Heat Sink Lh Rect Quantity Oooooouoodo go Grommet Scr No 8 10 Panel Hole 312 Sq 500 High Circuit Card Assy Control W Program Circuit Card Assy Control Aux Power W Program Stand Off Support PC Card 187 Dia W P amp l 375 Housing Plug Pins Service Kit RC1 Housing Plug Pins Housing Plug Pins Housing Plug Pins Service Kit RC2 Service Kit RC3 Service Kit RC5 Service Kit RC7 Service Kit RC8 Service Kit RC9 Service Kit RC10 Service Kit RC11 Supplementary Protector Man Reset 1P 10A 250VAC Frict Supplementary Protector Man Reset 1P 2 5A 250VAC Frict Panel Rear Standard Supplementary Protector Man Res
70. not related to personal injury 1 2 Arc Welding Hazards A 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 A Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill 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 e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if requir
71. ntinued Oum Rens 218 183 Rept Assy Tw Lk Insul Fem Tweco Type Fac Op Includes 2 E 209 473 Rept Twist Lock Tweco Style Female Power 1 OPEM 185 712 Insulator Bulkhead Front oe etae ete veste d e Le 195 713 Insulator Bulkhead Rear usara cra anita d ODD ia 185 714 Washer Tooth 22Mmid X 31 5Mmod 1 310 1Mmt Intern 1 LA bash ad dink de eed he de 185 717 Nut M20 1 5 1 00Hex 19H Brs Locking 1 MR 185 718 O Ring 0 989 Id X 0 070 H posu dn e un dC ed SE ui stas E E E 186 228 O Ring 0 739 Id X 0 070 H uso den dre mae E Nameplate Power Order by Model and Serial Number 1 LR OO AURA ad ed 240 959 Lapel PROCESS 223214 ede roe o ee b Ced d NL ERA Mie Dae 1 TU A E E 218041 Door W Quick Access Ball Fasteners 1 o PEPPER 175 A BOX LOUVOT irr ieaie ARE eon debeo dba acd doe utc Oed ane 1 pl OO b ctos Ata sui d Sd eve Label Order by Model and Serial Number 1 20 A M 174991 Knob Pointer 1 250 Dia X 250 Id W Spring Clip 21 2 eng ch lt 231 468 Nut 375 32 56Hex 22H Brs Conical Knurl 1 AN PPP 231 469 Nut 500 28 69Hex 28H Brs Conical Knurl 1 X prec ER Nameplate Connection Order by Model and Serial Number 1 O eich anche eae Nameplate Order by Model and Serial Number
72. on the Left Display HOT T adjusts the Hot Start Time to Adaptive Hot Start AUTO or from Min 1 to Max 50 Adapt ive Hot Start AUTO automatically chooses a default Time The Min 1 setting results in no hot start time Higher numbers result in longer start time Use this mode for Air Carbon Arc CAC A cutting and gouging For best results adjust dig setting to maximum OM 237 881 Page 39 8 4 Optional EON Open Circuit Voltage OCV Welding Modes Notes OM 237 881 Page 40 Low OCV Operation The unit can be optionally config ured for low open circuit voltage OCV operation in Stick and Scratch Start TIG modes When the unit is configured for low OCV op eration only a low sensing voltage approximately 15 VDC is present between the electrode and the workpiece prior to the electrode touching the workpiece Consult a Factory Authorized Service Agent for information regarding how to configure the unit for low OCV weld ing operation SECTION 9 MAINTENANCE amp TROUBLESHOOTING 9 1 Routine Maintenance J 4 E a Disconnect power Maintain more often af before maintaining during severe conditions 3 Months Replace 2 Repair Or Damaged Or P Replace cues ed Unreadable U XO Cracked orch Body Labels b Cables Repair Or Replace gt Cracked Cables And Cords Clean zu Anp Tighten Weld oe Connections D 6 Months _
73. ons 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 Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter 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 E SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement 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 e 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 comprim en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir
74. ot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et 87 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 e 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 237 881 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et 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 en
75. ounding 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 8 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout de vice and place switch in the On posi tion inputi 2011 03 803 766 C 4 10 Connecting 3 Phase Input Power e A Installation must meet all National E and Local Codes have only quali fied persons make this installation Disconnect and lockout tagout in put power before connecting input conductors from unit A Always connect green or green yellow conductor to supply GND PE Earth Ground grounding terminal first and never toa line terminal C7 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 between 208 and 575 VAC without removing cover to relink the power source See rating label on unit and check input voltage available at site For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 5 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 ye
76. ps Indicator is lit under the Right Display the Adjust Control is used to set desired preset amperage A remote control is required to turn on the weld output OM 237 881 Page 38 CF7 If the remote control has an amperage adjustment the adjustment will func tion as a percentage of the preset am perage Pressing the Setup Button allows adjust ment of Arc Control Hot Start Current and Hot Start Time For best results at the end of the weld pull back the electrode quickly to extin guish the arc Arc Control Dig Press the Setup Button so the Arc Control indicator is lit DIG appears on the Left Dis play and the corresponding dig setting ap pears on the Right Display Rotate Adjust Control to select desired dig setting from O to 100 Dig control allows the arc characteristics soft versus stiff to be changed for specific applications and electrodes Lower the dig setting for smooth running electrodes like E7018 and increase the dig setting for stiff er more penetrating electrodes like E6010 Press the Setup Button repeatedly until the Arc Control light goes out to return to ad justment of preset amperage Programmable Hot Start Press the Setup button repeatedly until HOT S appears on the Left Display HOT S adjusts the Hot Start Amperage to Adaptive Hot Start AUTO or from Min 1 to Max 50 Adaptive Hot Start AUTO automatic ally chooses a default amperage The Min 1 setting results in no
77. r 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 rep at 920 735 4505 Miller or 1 800 332 3281 Hobart Ref S 0007 J 2011 07 OM 237 881 Page 14 4 5 Remote 14 Receptacle Information LA remore 14 Socket Socket Information A 24 volts AC Protected by supplementary protect 24 VOLTS AC or CB2 OUTPUT CONTACTOR B Contact closure to A completes 24 volts AC contactor control circuit 115 volts AC Protected by supplementary pro 115 VOLTS AC tector CB1 OUTPUT CONTACTOR J Contact closure to completes 115 volts AC contactor control circuit C Output to remote control 0 to 10 volts DC 10 volts DC in MIG mode D Remote control circuit common E 0 to 10 volts DC input command signal from REMOTE remote control OUTPUT CONTROL L Wirefeed speed command 0 to 10 volts DC out put signal from wire feeder M CC CV Select O to 10 volts DC Wirefeed speed common AIV 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 K Chassis common The remaining sockets are not used 4 6 Optional 115 Volts AC Duplex Receptacle And Supplementary Protectors 1 115V 10 Amp AC Receptacle Power is shared between duplex re
78. ration If this display is shown have a qualified electrician check the input voltage Help 8 Display Indicates a malfunction in the secondary power circuit of the unit If this display is shown contact a Factory Authorized Service Agent Help 25 Display Indicates machine has reached duty cycle limits see Section 3 4 Unit must be left on to power the fan for cooling Operation will continue when unit has cooled 9 4 Troubleshooting Trouble Remedy No weld output unit completely inop Place line disconnect switch in On position see Sections 4 9 and 4 10 erative Check and replace line fuse s if necessary or reset circuit breaker See Sections 4 9 and 4 10 Check for proper input power connections see Sections 4 9 and 4 10 No weld output meter display On Input voltage outside acceptable range of variation see Section 4 8 Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 3 4 Erratic or improper weld output Use proper size and type of weld cable see Section 4 4 Clean and tighten all weld connections Check for correct polarity No 115 volts AC output at optional du Reset supplementary protector CB1 see Section 4 6 plex receptacle or Remote 14 recep tacle No 24 volts AC output at Remote 14 Reset supplementary protector CB2 see Section 4 6 receptacle Notes OM 237 881 Page 43 OM
79. s E7 Other normal gas mixtures can be used by adjusting arc length and sharp arc Use the program closest to your gas mixture and wire type and Size Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 237 881 Page 32 7 6 Remote Process Select gt Q Decimal point indicates wire feeder right side is active My 4 Decimal point indicates wire feeder right side is active This power source can be used with wire feeders that support Remote Process Se lect This feature allows the operator to switch the active welding process between MIG and Pulsed MIG at the wire feeder To determine if the welding system is Remote Process Select capable connect the wire feeder to the power source and review the power source display variations shown be low E Whenused with an XMT power source the Process Select knob must be set to Pulsed MIG for Remote Process Select to be active Power Source Display Wire Feeder with Remote Process Select Not Detected When the power source Right Display is blank a wire feeder with Remote Process Select is not detected Set the active weld process at the power source Power Source Display Wire Feeder with Remote Process Select Detected When the power source Right Display is MIG a wire feeder with Remote Process Se lect is detected and set for MIG operation The active weld proce
80. s designed for the specific application maintain them unless they are properly prepared according to AWS F4 1 see and associated parts in good condition safety Standards e Turn face away from valve outlet when opening cylinder valve e Do not weld where the atmosphere may contain flammable dust e Keep protective cap in place over valve except when cylinder is in gas or liquid vapors such as gasoline use or connected for use e Connect work cable to the work as close to the welding area as e 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 e Read and follow instructions on compressed gas cylinders hazards e Do not use welder to thaw frozen pipes OM 237 881 Page 2 associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance 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 KC FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of
81. s shown in the Right Dis play with the Amps Indicator lit Operation While the Amps Indicator is lit under the Right Display the Adjust Control is used to set desired preset amperage Pressing the Setup Button allows adjust ment of Arc Control Hot Start Current and Hot Start Time For best results at the end of the weld pull back the electrode quickly to extin guish the arc Arc Control Dig Press the Setup Button so the Arc Control indicator is lit DIG appears on the Left Dis play and the corresponding dig setting ap pears on the Right Display Rotate Adjust Control to select desired dig setting from O to 100 Dig control allows the arc characteristics soft versus stiff to be changed for specific applications and electrodes Lower the dig setting for smooth running electrodes like E7018 and increase the dig setting for stiff er more penetrating electrodes like E6010 Press the Setup Button repeatedly until the Arc Control light goes out to return to ad justment of preset amperage Programmable Hot Start Press the Setup button repeatedly until HOT S appears on the Left Display HOT S adjusts the Hot Start Amperage to Adaptive Hot Start AUTO or from Min 1 to Max 50 Adaptive Hot Start AUTO automatic ally chooses a default amperage The Min 1 setting results in no hot start amperage Higher numbers result in higher start am perage Press the Setup button again so HOT T ap pears
82. se of shielding gas is dependant on Wire Type C7 The connection diagram illus trates DCEP reverse polarity suitable for all wires except self shielded FCAW The ma jority of self shielded FCAW wires require DCEN straight polarity e K 7 WEN 7 EN i NUS YI 804 843 B OM 237 881 Page 34 7 8 V Sense Feeder Welding Mode GMAW FCAW Process a Manufactured Under the Following US Patents 5 601 741 5 642 260 5 902 150 6 002 103 6 115 273 6 193 548 6 239 407 6 266 257 6 625 046 6 611 189 6 426 888 Other Patents Pending m DL uu l e COL LIFFARC TIG qe CL STICK V SENSE FEEDER SCRATCH 4 START TIG ADJUST cd C Arc Control Q v ED 5 A Weld terminals are energized at all times in V Sense Feeder welding mode Mode Switch Volts Indicator Left Display Right Display Adjust Control Wire Type Indicator Arc Control Indicator Setup Button Gas Type Indicator ON Oa BR N Setup For typical system setup connections refer to Section 7 7 Rotate Mode Switch to V SENSE FEEDER position as shown The Left Display toggles between open cir cuit voltage and preset voltage with the Volts Indicator lit Operation While the Volts Indicator is lit under the Left Display the Adjust Control is used to set desired preset voltage The Left
83. settings narrow the arc cone re duces puddle fluidity and crowns the weld bead appearance 7 Each Wire and Gas Type combination has independent Arc Length and Shar pArc settings These settings are pre served when the unit is turned off Arc Length Trim Trim corresponds to the level of energy needed to burn off the welding electrode As wire feed speed increases a higher trim setting is required to burn off the additional wire The trim setting appears in the Left Display when the Arc Length Indicator is lit Trim can be adjusted from 0 to 100 Prior to arc initiation the unit displays the letter R and a reference wire speed IPM on the Right Display The reference wire speed can be used as a starting point for the wire speed setting at the feeder The wire speed and trim can then be further ad justed to achieve the desired arc length The Configuration Option Menu see Sec tion 5 3 can be used to change the Arc Length setting from trim 0 to 100 to aver age arc voltage Average arc voltage can be used as an alternative method to set the Pulsed MIG welding arc with the same pa rameters voltage and wire speed as a conventional MIG arc Lower voltage set tings correspond to tighter arc lengths while higher voltage settings correspond to lon ger arc lengths If the voltage mode is se lected the average preset voltage will be displayed on the Left Display with the Volts Indicator lit SECTION 8 SMAW CAC
84. ss can only be changed at the wire feeder Power Source Display Wire Feeder with Remote Process Select Detected and Set for Pulsed MIG When the power source Right Display is PULS a Remote Process Select wire feeder is detected and is set for Pulsed MIG opera tion The active weld process can only be changed at the wire feeder Using a Dual Wire Feeder with Remote Process Select When using a dual wire feeder with Remote Process Select different weld programs for the left and right side can be selected The power source MIG and Pulsed MIG pro grams for the left side of wire feeder are se lected with the left side of the wire feeder act ive The power source MIG and Pulsed MIG programs for the right side are selected with the right side of the wire feeder active When the right side of the wire feeder is active the power source Right Display will show a decimal point in the lower right hand corner as shown Power Source Display Dual Wire Feed er with Right Side Active and Set for MIG Power Source Display Dual Wire Feed er with Right Side Active and Set for Pulsed MIG OM 237 881 Page 33 7 7 Typical Connection For Voltage Sensing Feeder GMAW GMAW P FCAW Process A Turn off power before mak ing connections Positive Weld Output Terminal Negative Weld Output Terminal Ground Cable to Workpiece Workpiece Voltage Sensing Clamp Gun Gun Trigger Receptacle Wire Feeder Gas Hose 10 Gas Cylinder U
85. strictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 237 881 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website 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 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website w
86. tor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 237 881 Page 17 4 9 Connecting 1 Phase Input Power a PA 2 1444421172 SE R Q NS a Iw N gt GND PE Earth Ground 2 D S D T SEOSE 35 CELYXY X Tools Needed le OM 237 881 Page 18 A Installation must meet all Na tional and Local Codes have only qualified persons make this installation A Disconnect and lockout tag out input power before con necting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never to a line termi nal C7 The Auto Line circuitry in this unit automatically adapts the power source to the primary voltage be ing applied Check input voltage avallable 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 See rating label on unit and check in put voltage available at site 1 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 switch shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow gr
87. ts in inverter weld ing power sources AFTER removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns iiim OM 237 881 Page 1 e Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous contact tio when not in use Weno pisdices tumesiand gases iBreaihilg e Wear oil free protective garments such as leather gloves heavy these fumes and gases can be hazardous to your shirt cuffless trousers high shoes and a cap health e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Keep your head out of the fumes Do not breathe the fumes e After completion of work inspect area to ensure it is free of sparks If inside ventilate the area and or use local forced ventilation at the glowing embers and flames arc to remove welding fumes and gases e Use only correct fuses or circuit breakers Do not oversize or by If ventilation is poor wear an approved air supplied respirator pass them Read and understand the Material Safety Data Sheets MSDSs e Follow requirements in OSHA 1910 252 a 2 iv an
88. uincy MA 02269 t l phone 800 344 3555 site Internet www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou ave
89. up Button repeatedly until the Arc Control indicator is lit INDU appears on the Left Display and the corresponding in ductance setting appears on the Right Dis play Rotate Adjust Control to select desired in ductance setting from 0 to 100 Use lower inductance settings to stiffen the arc and re duce puddle fluidity Use higher inductance settings to soften the arc and increase puddle fluidity Refer to the MIG Wire and Gas Selection Table see Section 7 3 for suggested in ductance setting for the specific wire and gas being used Press the Setup Button to return to adjust ment of preset voltage t7 Each Wire and Gas Type combination has independent preset voltage and in ductance settings These settings are preserved when the unit is turned off OM 237 881 Page 29 7 3 MIG Wire and Gas Selection Table WIRE TYPES GAS TYPES DEFAULT INDUCTANCE ve T zd ARGN CO2 ARGON CARBON DIOXIDE ARGN OXY ARGON OXYGEN 052 1 4 STL Steel 035 0 9 STL 045 1 2 STL CO2 CARBON DIOXIDE 10 035 0 9 FCAW C 045 1 2 FCAW ARGN CO2 ARGON CARBON DIOXIDE oan ee 052 1 4 FCAW CO2 CARBON DIOXIDE 1 16 1 6 FCAW 045 1 2 MCOR Metal Core 052 1 4 MCOR ARGN CO2 ARGON CARBON DIOXIDE 30 1 16 1 6 MCOR IN 035 0 9 SSTL TRI MIX TRI GAS MIXTURE a 045 1 2 SSTL ARGN OXY ARGON OXYGEN 035 0 9 AL4X 4000 Series 040 1 0 AL4X 4000 Series 3 64 1 2 AL4X 4000 Series 1
90. ww osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSc gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder 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 then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2010 03 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s 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 o

Red-D-Arc EXTREME 360 Specifications

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