Miller PipePro XC Owner's Manual

OM-269631D 2016−07

Processes

MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding

Flux Cored (FCAW) Welding

Stick (SMAW) Welding

Description

Arc Welding Power Source
Wire Feeder

R

PipePro XC

Welding System

(380-400 Volt Model)

CE

Visit our website at

www.MillerWelds.com

File: MIG (GMAW)

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................

2-1. Symboles utilisés 5.....................................................................

2-2. Dangers relatifs au soudage à l’arc 5......................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....

2-4. Proposition californienne 65 Avertissements 8..............................................

2-5. Principales normes de sécurité 8.........................................................

2-6. Informations relatives aux CEM 8.........................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Manufacturer’s Warning Label Definitions 9.................................................

3-2. Miscellaneous Symbols And Definitions 12..................................................

SECTION 4 − SPECIFICATIONS 13..............................................................

4-1. Serial Number And Rating Label Location 13................................................

4-2. Unit Specifications 13....................................................................

4-3. Dimensions And Weight 13...............................................................

4-4. Environmental Specifications 14...........................................................

4-5. MIG Duty Cycle and Overheating 15.......................................................

4-6. Stick Duty Cycle and Overheating 17.......................................................

SECTION 5 − INSTALLATION 18................................................................

5-1. Selecting A Location 18..................................................................

5-2. Equipment Connection Diagram For Self-Shielded Flux Core 19................................

5-3. Equipment Connection Diagram For MIG/RMD 20............................................

5-4. Remote 14 Accessory Receptacle Information 21............................................

5-5. Power Source Remote 14 Wire Feeder Control Receptacle Information 21.......................

5-6. Supplementary Protector CB2 22..........................................................

5-7. Connecting To Weld Output Terminals 23...................................................

5-8. Connecting Weld Output Cables 23........................................................

5-9. Weld Output Terminals And Selecting Cable Sizes* 24........................................

5-10. Electrical Service Guide 25...............................................................

5-11. Connecting 3-Phase Input Power 26.......................................................

5-12. Proper Ring Terminal Connection To Work Sense Lead 28.....................................

5-13. Connecting Work Sense Lead And Work Cable To Clamp 28...................................

5-14. Wire Feeder Remote 14 Control Receptacle Information 29....................................

5-15. Wire Feeder Trigger Receptacle Information 29..............................................

5-16. Installing And Aligning Wire Guide And Drive Rolls 30.........................................

5-17. Connecting Welding Gun 31..............................................................

5-18. Connecting Shielding Gas 32.............................................................

5-19. Connecting Weld Cable And Work Sense Lead 32............................................

5-20. Installing And Threading Welding Wire 33...................................................

TABLE OF CONTENTS

SECTION 6 − OPERATION 34...................................................................

6-1. Operational Terms 34....................................................................

6-2. CE Welding Power Source Controls 35.....................................................

6-3. Welding Power Source Operation Description 36.............................................

6-4. Memory Card Slot 37....................................................................

6-5. Feeder Units Switch 38..................................................................

6-6. PipePro XC RMD Feeder Front Panel Controls 39............................................

6-7. PipePro XC RMD Feeder CE Operation Description 40........................................

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 42.......................................

7-1. Routine Maintenance 42.................................................................

7-2. Blowing Out Inside of Unit 42.............................................................

7-3. Cleaning Debris From Shielding Gas Filter Fitting 43..........................................

7-4. Restoring Factory Defaults 44.............................................................

7-5. Viewing Software Revision 44.............................................................

7-6. Power Source Calibration Procedure 44....................................................

7-7. Removing Right Side Panel and Measuring Input Capacitor Voltage 45..........................

7-8. Welding Power Source And Feeder Diagnostic Help Codes 46.................................

7-9. Troubleshooting Welding Power Source/Wire Feeder Issues 48.................................

7-10. Welding Power Source Troubleshooting 49..................................................

7-11. Wire Feeder Troubleshooting 49...........................................................

SECTION 8 − ELECTRICAL DIAGRAM 50........................................................

SECTION 9 − PARTS LIST 54...................................................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the

product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

PipePro 400 XC 380/400V CE

PipePro XC RMD Feeder

Council Directives:

S 2006/95/EC Low Voltage
S 2004/108/EC Electromagnetic Compatibility
S 2011/65/EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment

Standards:

907675
300844

S IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
S IEC 60974-5:2013 Arc welding equipment – Part 5: Wire feeders
S IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements

Signatory:

December 3, 2014

_____________________________________ ___________________________________________

David A. Werba

MANAGER, PRODUCT DESIGN COMPLIANCE

Date of Declaration

270662A

EMF DATA SHEET FOR ARC WELDING POWER SOURCE

Product/Apparatus Identification

Product

PIPEPRO 400XC 380/400V (CE) 907675

Compliance Information Summary

Applicable regulation Directive 2014/35/EU

Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC

Applicable standards IEC 62822-1:2016, IEC 62822-2:2016

Intended use ☒ for occupational use ☐ for use by laymen

Non-thermal effects need to be considered for workplace assessment ☒ YES ☐ NO

Thermal effects need to be considered for workplace assessment ☐ YES ☒ NO

☒ Data is based on maximum power source capability (valid unless firmware/hardware is changed)

Stock Number

☐ Data is based on worst case setting/program (only valid until setting options/welding programs are changed)

☐ Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)

Occupational exposure is below the Exposure Limit Values (ELVs) ☒ YES ☐ NO
for health effects at the standardized configurations (if NO, specific required minimum distances apply)

Occupational exposure is below the Exposure Limit Values (ELVs) ☐ n.a ☒ YES ☐ NO
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed)

Occupational exposure is below the Action Levels (ALs) at the ☐ n.a ☐ YES ☒ NO
standardized configurations (if applicable and NO, specific signage is needed)

EMF Data for Non-thermal Effects

Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)

Head

Sensory Ef

fects
Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm
ELV EI @ standardized distance 0.35 0.35 0.55 0.31 0.71

Required minimum distance 2 cm 2 cm 4 cm 1 cm 2 cm

Distance where all occupational ELV Exposure Indices fall below 0.20 (20%) 40 cm

Health Ef

fects

Trunk

Limb (hand) Limb (thigh)

Distance where all general public ELV Exposure Indices fall below 1.00 (100%) 448 cm

Tested by: Tony Samimi Date tested: 2016-01-28

275551-A

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

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 ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

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

there is a danger of falling.

D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in 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 unavoid­able 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 volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D 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).

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

. Indicates special instructions.

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

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

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

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

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

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in
use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

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

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-269631 Page 1

FUMES AND GASES can be hazardous.

)

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

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

arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
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.

D 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).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

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

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise lev-

el is high.

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

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.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.

D Do not use welder to thaw frozen pipes.

OM-269631 Page 2

workpiece, and hot equipment can cause fires and

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.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D 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.

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

Owner’s Manuals, industry standards, and national, state, and
local codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

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

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

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts.
D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

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

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

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

OM-269631 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 & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], 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: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

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.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: 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: [phone], 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, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment 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.

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. Do not 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 recom­mended.

OM-269631 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

fre_som_2015−09

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.

2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce ma­nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec­tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc­tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimen­tation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.

D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

D Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de
tomber.

D Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

D D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée. En outre, ne pas travailler seul !

. Indique des instructions spécifiques.

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
afférant pour les actions nécessaires afin d’éviter le danger.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor­mes de sécurité).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî­ner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près pos­sible de la soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

D Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

D Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

D Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.

OM-269631 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

provoquer des brûlures.

D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant

de travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génèr

des rayons visibles et invisibles intenses (ultraviolets
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l
peau. Des étincelles sont projetées pendant le soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un

incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels

que des réservoirs, tambours ou des conduites peut

provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des

pièces chaudes et des équipements chauds peut provoquer des incen­dies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un sur-

OM-269631 Page 6

chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.

D Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

D Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

D Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

D Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

D Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de ref­roidissement des soudures, elles risquent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

D Le soudage, l’écaillement, le passage de la pièce à

LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

D Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

D Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut

affecter l’ouïe.

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser

si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est

les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

endommagée, elle peut exploser. Du fait que

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

D Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de pro-

duits inflammables.

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut

provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.

D Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

D Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et

les yeux.

D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé­cuter dans un endroit sûr lorsque l’on porte l’équipement ho­mologué de protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les cir­cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent
causer des blessures.

D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent
causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal­lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

OM-269631 Page 7

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

D Le rayonnement haute fréquence (H.F.) peut

pements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

provoquer des interférences avec les équi-

D Veiller à ce que tout l’équipement de la zone de soudage soit com-

D Pour réduire la possibilité d’interférence, maintenir les câbles de

D Veiller à souder à une distance de 100 mètres de tout équipement

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

D En cas d’interférences après avoir pris les mesures précédentes,

2-4. Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

patible électromagnétiquement.

soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).

électronique sensible.

conformément à ce mode d’emploi.

il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], 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: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: 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: [phone], 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, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

OM-269631 Page 8

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité 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
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

SECTION 3 − DEFINITIONS

3-1. Manufacturer’s Warning Label Definitions

Warning! Watch Out! There are possible hazards as shown by the symbols.

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Protect yourself from electric shock by insulating yourself from work and ground.

Safe1 2012−05

Safe2 2012−05

Safe3 2012−05

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Keep flammables away from welding. Do not weld near flammables.

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe6 2012−05

Safe8 2012−05

Safe10 2012−05

Safe12 2012−05

Safe14 2012−05

Do not weld on drums or any closed containers.

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

Safe16 2012−05

Safe20 2012−05

OM-269631 Page 9

Disconnect input plug or power before working on machine.

When power is applied failed parts can explode or cause other parts to explode.

Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.

Always wear long sleeves and button your collar when servicing unit.

After taking proper precautions as shown, connect power to unit.

Safe5 2012−05

Safe26 2012−05

Safe27 2012−05

Safe28 2012−05

Safe29 2012−05

Do not discard product with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.

Safe37 2012−05

Beware of electric shock from wiring.

Safe94 2012−08

Disconnect input plug or power before working on machine.

Safe30 2012−05

Connect Green Or Green/Yellow grounding conductor to ground terminal first.
Connect input conductors (L1, L2, L3) to line terminals.

Safe36 2012−05

Become trained and read the instructions and labels before working on machine.

Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.

OM-269631 Page 10

Safe35 2012−05

Safe57 2012−05

?

V

?

A

Consult rating label for input power requirements.

Safe34 2012−05

Drive rolls can injure fingers.

Safe32 2012−05

Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.

Safe33 2012−05

Do not use one handle to lift or support unit.

Safe31 2012−05

Environmental Protection Use Period (China)

Safe123 2016−06

Become trained and read the instructions before working on the
machine or welding.

Safe65 2012−06

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

Become trained and read the instructions before working on the
machine or welding.

Safe40 2012−05

V

V

Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor

>5min

=<60°

V

voltage, and be sure it is near 0 before touching any parts.

Safe43 2012−05

Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.

Use a proper cart to move unit.

Safe44 2012−05

OM-269631 Page 11

3-2. Miscellaneous Symbols And Definitions

A

U

Hz

IP

Amperage

Rated No Load

Voltage (OCV)

0

SD Logo Is A

Trademark Of The

SD−3C, LLC

Internal Protection

Gas Input Filter Save To Memory

Direct Current

(DC)

Off On Circuit Breaker

Negative Positive

Increase Line Connection

1

Suitable for Some

Primary Voltage

Hazardous

Locations

Three Phase Single Phase

Volt Sense Input

U

I

2

2

14

Hertz

Rating

U

s

VS

Alternating

Current (AC)

Shielded Metal Arc

Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Conventional
Load Voltage

Rated Welding

Current

Remote 14

V

X

%

I

1

Voltage

Protective Earth

(Ground)

High Frequency -

General

Three Phase Static

Frequency Con-

verter-

Transformer-

Rectifier

Duty Cycle

Percent

Rated Supply

Current

Flux Cored Arc

Welding (FCAW)

Recall From Mem-

ory

Notes

Hour Meter Select Electrode Press

OM-269631 Page 12

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number for the power source is located on the front, and the rating information is located on the rear. Suitcase feeder serial number and
rating information is located inside the case near the weld cable. Use rating label 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. Unit Specifications

A. Welding Power Source Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-10 and 5-11 for connecting input

power.

Input

Power

Three
Phase

To appropriately size circuit protection see Section 5-10.

Welding
Process

Stick

MIG

Flux

Cored

Rated Welding

Output

350 A @ 34 Volts

DC, 100% Duty

Cycle

@ 50° C (122° F)
400 A @ 34 Volts

DC, 100% Duty

Cycle

@ 50° C (122° F)
400 A @ 34 Volts

DC, 100% Duty

Cycle

@ 50° C (122° F)

Amperage

Range

Setting (CC

Process)

40 − 350 — —

— — 10-39 27.1 25.7 18.0 18.0 15.5 15.6

— — 10-39 27.1 25.7 18.0 18.0 15.5 15.6

Setting (CV

Voltage

Range

Process)

Maximum

Open-

Circuit

Voltage

DC

80

Amperes Input At

Rated Load

Output 50/60 Hz,

Three-Phase

380 V 400 V 380 400 380 400

23.5 22.7 15.7 15.9 13.2 13.2

KVA KW

B. Wire Feeder Specifications

Input Power

24 Volts AC

9 Amperes

Welding Power

Source Type

PipePro XC 1.3 To 12.7 mpm

Wire Feed Speed

Range

(50 To 500 ipm)

4-3. Dimensions And Weight

Hole Layout Dimensions

A 464 mm (18-1/4 in.)

B 305 mm (12 in.)

C 178 mm (7 in.)

D 565 mm (22-1/4 in.)

E 686 mm (27 in.)

10.5 mm (27/64 in.)

F

4 Holes

Wire Diameter

Range

0.9 To 1.2 mm

(.035 To .045 in.)

Max Spool

Weight: 15 kg

(33 lb)

A
B

C

D

Welding

Circuit
Rating

100 Volts,

500 Amperes,

100% Duty

Cycle

E

Overall Dimensions

Length: 508 mm (20 in.)

Width: 203 mm (8 in.)

Height: 438 mm

(17-1/4 in.)

705 mm

(27-3/4 in.)

Weight

15.2 kg

(33-1/2 lb)

464 mm

(18-1/4 in.)

Weight:

56.7 kg (125 lb)

381 mm

(15 in.)

F

Ref. 250 702-B

OM-269631 Page 13

4-4. Environmental Specifications

A. IP Rating

IP Rating

IP23

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless

B. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−

voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con­ducted as well as radiated disturbances.

This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Z
VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary,
that the system impedance complies with the impedance restrictions.

at the point of common coupling is less than 19.6 m (or the short−circuit power Ssc is greater than 8,348,769

max

C. China EEP Hazardous Substance Information

质量

China EEP Hazardous Substance Information

部

Component Name

(适)

(if applicable)

黄铜铜部

Brass and Copper Parts

装

Coupling Devices

装

Switching Devices

配

Cable and Cable
Accessories



Batteries

表SJ/T 11364规.

This table is prepared in accordance with China SJ/T 11364.
O:

表该质该部质量GB/T26572规限量要.

Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.

X:

表该质该部质量超GB/T26572规限量要.

Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.

质

Hazardous Substance

铅

Pb

X

X O O O O O

O O X O O O

X O O O O O

X O



Hg

O O O O O

sheltered.

镉

Cd

O O O O

铬

Cr6

苯

PBB

IP23 2014−06

ce-emc 1 2014-07

苯醚

PBDE

限SJ/Z11388规.

The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.

D. Temperature Specifications

Operating Temperature Range Storage Temperature Range

14 to 104 °F (−10 to 40°C) −4 to 131 °F (−20 to 55°C)

OM-269631 Page 14

EEP_2016−06

Temp_2016-07

4-5. MIG Duty Cycle and Overheating

A. 405 C (1045 F) Operation

100% Duty Cycle At 450 Amperes 60% Duty Cycle At 565 Amperes

Duty Cycle is percentage of 10 min­utes that unit can weld at rated load
without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Overheating

Continuous Welding

0

Minutes

6 Minutes Welding 4 Minutes Resting

A/V

15

OR

Reduce Duty Cycle

duty1 4/95 − Ref. 257 025-A

OM-269631 Page 15

B. 505 C (1225 F) Operation

100% Duty Cycle At 400 Amperes 60% Duty Cycle At 500 Amperes

Duty Cycle is percentage of 10 min­utes that unit can weld at rated load
without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Continuous Welding

Overheating

C. 605 C (1405 F) Operation

100% Duty Cycle At 300 Amperes 60% Duty Cycle At 375 Amperes

0

Minutes

6 Minutes Welding 4 Minutes Resting

A/V

15

OR

Reduce Duty Cycle

duty1 4/95 − Ref. 257 025-A

Duty Cycle is percentage of 10 min­utes that unit can weld at rated load
without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Continuous Welding

Overheating

OM-269631 Page 16

0

Minutes

6 Minutes Welding 4 Minutes Resting

A/V

15

OR

Reduce Duty Cycle

duty1 4/95 − Ref. 257 025-A

4-6. Stick Duty Cycle and Overheating

A. 405 C (1045 F) And 505 C (1225 F) Operation

100% Duty Cycle At 350 Amperes

Continuous Welding

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage,
voltage, wire feed speed, or duty
cycle before welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Overheating

B. 605 C (1405 F) Operation

0

15

Minutes

100% Duty Cycle At 300 Amperes

A/V

OR

Reduce Duty Cycle

duty1 4/95 − Ref. 257 025-A

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage,
voltage, wire feed speed, or duty
cycle before welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Overheating

Continuous Welding

0

15

Minutes

A/V

OR

Reduce Duty Cycle

duty1 4/95 − Ref. 257 025-A

OM-269631 Page 17

SECTION 5 − INSTALLATION

5-1. Selecting A Location

Movement

Location And Airflow

2

OR

1

3

! Do not move or operate

unit where it could tip.

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

1 Lifting Forks

4

18 in.

(460 mm)

Extend forks beyond opposite side
of unit.

2 Lifting Handles
Use handles to lift unit.
3 Hand Cart
Use cart or similar device to move

unit.
4 Line Disconnect Device
Locate unit near correct input

power supply.

18 in.

(460 mm)

OM-269631 Page 18

loc_med 2015-04 - Ref. 250 702-B

5-2. Equipment Connection Diagram For Self-Shielded Flux Core

1

3

9

5

2

! Turn Off wire feeder and

welding power source.

! Use only with the PipePro XC

Power Source.

1 PipePro XC Welding Power

Supply

2 Weld Cable To Feeder

Electrode Negative
3 Work Cable To Workpiece
Weld cable and work cable connec-

tions to power source.
4 Workpiece
5 Work Sense Lead
Connect work sense clamp to

workpiece.
6 Gun
7 Gun Trigger Receptacle
8 Wire Feeder
9 Feeder Control Cable

8

7

6

4

250 769-B

OM-269631 Page 19

5-3. Equipment Connection Diagram For MIG/RMD

1

11

2

3

9

10

8

! Turn Off wire feeder and

welding power source.

! Use only with the PipePro XC

Power Sources.

1 PipePro XC Welding Power

Supply
2 Weld Cable To Feeder
3 Work Cable To Workpiece
Weld cable and work cable connec-

tions to power source.
4 Workpiece
5 Work Sense Lead
Connect work sense clamp to

workpiece.
6 Gun
7 Gun Trigger Receptacle
8 Wire Feeder
9 Feeder Control Cable
10 Gas Hose
11 Gas Cylinder
Use of shielding gas is dependant

on wire type.

. Shielding gas pressure not to

exceed 90 psi (620 kPa).

5

4

7

6

OM-269631 Page 20

250 770-B

5-4. Remote 14 Accessory Receptacle Information

If a remote control is connected to the Remote 14 receptacle, the unit will automatically adjust output control to a primary/secondary configuration. In
this configuration, the Amperage Adjust knob on the unit becomes the primary and sets the maximum amperage output of the unit. The remote control
becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage Adjust knob setting.

Socket* Socket Information

AJ

K

B

L

C

D

I

NH

M

G

F

E

15 VOLTS DC

A 15 volts DC.

B Contact closure to A completes 15 volts DC

contactor control circuit.

C Output to remote control; +10 volts DC.

REMOTE

D Remote control circuit common.

CONTROL

E 0 to +10 volts DC input command signal from

remote control.

K Chassis common.

*The remaining sockets are not used.

Ref. 250 702-B

GND

5-5. Power Source Remote 14 Wire Feeder Control Receptacle Information

Remote 14 Feeder Control Socket* Socket Information

A, B 24 volts AC. Protected by supplementary

protector CB2.

24 VOLTS AC

SERIAL

COMMUNICATION

C, D 24 volts AC return. Connected to chassis

common. Completes 24 volts AC power supply
circuit to feeder.

J Isolated RS-485 (+) serial communication signal.

I Isolated RS-485 (−) serial communication signal.

Ref. 250 702-B

*The remaining sockets are not used.

POSITIVE VOLT SENSE

NEGATIVE VOLT SENSE

GND

H Isolated serial communication common.

G Positive weld output voltage sense signal.

F Negative weld output voltage sense signal.

K, N Chassis common.

OM-269631 Page 21

5-6. Supplementary Protector CB2

CB2

1 Supplementary Protector CB2
CB2 protects the 24 volts ac power

supply to the wire feeder.

1

Press button to reset supplementary
protector.

Notes

Ref. 250 702-B

OM-269631 Page 22

5-7. Connecting To Weld Output Terminals

! Turn off power before connecting

to weld output terminals.

! Do not use worn, damaged, under-

sized, or repaired cables.

1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Connect positive weld cable to Positive

(+) weld terminal and negative (−) cable
to Negative weld terminal.

. For welding output terminal connec-

tions see Sections 5-2 thru 5-3 for typ­ical connection processes.

1

2

5-8. Connecting Weld Output Cables

4

1

Do not place

anything between

weld cable terminal

and copper bar.

2

3

Tools Needed:

3/4 in. (19 mm)

Incorrect Installation

Ref. 250 702-B

803 778-B

! Turn off power before connecting to

weld output terminals.

! Failure to properly connect weld

cables may cause excessive heat
and start a fire, or damage your
machine.

1 Weld Output Terminal
2 Supplied Weld Output Terminal Nut
3 Weld Cable Terminal
4 Copper Bar
Remove supplied nut from weld output

terminal. Slide weld cable terminal onto

weld output terminal and secure with nut so
that weld cable terminal is tight against
copper bar. Do not place anything

between weld cable terminal and copper
bar. Make sure that the surfaces of the
weld cable terminal and copper bar are
clean.

OM-269631 Page 23

5-9. Weld Output Terminals And Selecting Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less

10 − 60%

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Duty

Cycle

AWG (mm2)

60 − 100%

Duty Cycle

AWG (mm2)

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 − 100% Duty Cycle

AWG (mm2)

350 ft

(105 m)

400 ft

(120 m)

Ref. S-0007-L 2015−02

Notes

OM-269631 Page 24

5-10. Electrical Service Guide Elec Serv 2014−01

NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions 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.

50 Hz Three Phase

Input Voltage (V) 380 400
Input Amperes (A) At Rated Output 27.1 25.7
Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG (mm2)

4

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG (mm2)

4

1

2

3

30 30
40 40
10

(5.26)10(5.26)

226
(69)

249
(76)

10

(5.26)10(5.26)

Reference: 2014 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 conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

OM-269631 Page 25

5-11. Connecting 3-Phase Input Power

8

4

9

3

= GND/PE
Earth Ground

10

7

L1

6

L2

L3

1

2

5

Tools Needed:

L1
L2

6

L3

43

OM-269631 Page 26

5/16 in.

input5 2016−04 Ref. 269 652

5-11. Connecting 3-Phase Input Power (Continued)

! Turn Off welding power source, and

check voltage on input capacitors
according to Section 7-7 before
proceeding.

! Installation must meet all National and

Local Codes − have only qualified per­sons make this installation.

! Disconnect and lockout/tagout input

power before connecting input
conductors from unit. Follow estab­lished procedures regarding the in­stallation and removal of lockout/
tagout devices.

! Make input power connections to the

welding power source first.

! Always connect green or green/yellow

conductor to supply grounding
terminal first, and never to a line
terminal.

See rating label on unit and check input
voltage available at site.

1 Input Power Conductors (Customer

Supplied Cord)

Select size and length of conductors using
Section 5-10. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.

Welding Power Source Input Power
Connections

2 Strain Relief (Customer Supplied)
Install strain relief of proper size for unit and

input conductors. Route conductors (cord)
through strain relief. Tighten strain relief.

S Use large strain relief for input conductor
size 8 and larger.

S Use small strain relief with reducing
washers for input conductor size 10.

3 Welding Power Source Grounding

Terminal

4 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding
conductor to machine grounding terminal first.

5 Welding Power Source Line Terminals

6 Input Conductors L1, L2, L3
Connect input conductors L1, L2, and L3 to

welding power source line terminals.
Reinstall side panel on welding power source.

Disconnect Device Input Power
Connections

7 Disconnect Device (switch shown in the

OFF position)
8 Disconnect Device Grounding Terminal
9 Disconnect Device Line Terminals
Connect green or green/yellow grounding

conductor to disconnect device grounding ter­minal first.

Connect input conductors L1, L2, and L3 to
disconnect device line terminals.

10 Over-Current Protection
Select type and size of over-current protec-

tion using Section 5-10 (fused disconnect
switch shown).

Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.

Notes

Input5 2016−04

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-269631 Page 27

5-12. Proper Ring Terminal Connection To Work Sense Lead

2

1

If work sense lead is cut or broken at end
with ring terminal, be sure that new ring ter­minal is connected as shown.

Tools Needed:

1 Jacket
2 Insulated Tape Or Heat-Shrink

Tubing

3 Center Conductor

4 Ring Terminal 1/2 in. Opening

5-13. Connecting Work Sense Lead And Work Cable To Clamp

3

1 Work Sense Lead
2 Work Cable
3 Clamp

4

Ref. 239 780-B

. Be sure that work sense lead

ring terminal is on top of work
cable ring terminal when
connecting to clamp.

Connect work sense lead and work
cable to clamp.

1

2

Tools Needed:

1/2 in.

1/2 in.

OM-269631 Page 28

3

805 030-A

5-14. Wire Feeder Remote 14 Control Receptacle Information

Remote 14 Feeder Control Socket* Socket Information

A, B 24 volts AC. Protected by supplementary

protector CB2.

Ref. 250 703-A

*The remaining sockets are not used.

24 VOLTS AC

SERIAL

COMMUNICATION

POSITIVE VOLT SENSE

NEGATIVE VOLT SENSE

GND

C, D 24 volts AC return. Connected to chassis

common. Completes 24 volts AC power supply
circuit to feeder.

J Isolated RS-485 (+) serial communication signal.

I Isolated RS-485 (−) serial communication signal.

H Isolated serial communication common.

G Positive weld output voltage sense signal.

F Negative weld output voltage sense signal.

K, N Chassis common.

5-15. Wire Feeder Trigger Receptacle Information

Remote 14 Feeder Control Socket Socket Information

Trigger

Dual Schedule

Ref. 250 703-A

1

Contact closure between 1 and 2 energizes

system output

2

3

Contact closure between 3 and 4 changes to
alternative schedule

4

OM-269631 Page 29

5-16. Installing And Aligning Wire Guide And Drive Rolls

Installing Wire Guide And

Drive Rolls

5

4

3

1

2

Installing Wire Guide And Drive
Rolls:

1 Drive Roll Nut
2 Drive Roll Carrier
Turn nut one click until lobes of nut

line up with lobes of drive roll carrier.
3 Drive Roll
Slide drive roll onto drive roll carrier.

Turn nut one click.
Repeat procedure for top drive roll.
4 Inlet Wire Guide Screw

5 Inlet Wire Guide
Loosen securing screw. Install inlet

guide so inlet guide screw is
centered in groove in guide, or so tip
is as close to drive rolls as possible
without touching. Tighten screw.

Aligning Wire Guide And Drive
Rolls:

View is from top of drive rolls look­ing down with pressure assembly
open.

6 Drive Roll Securing Nut
7 Drive Roll
8 Wire Guide
9 Welding Wire
10 Drive Gear
Turn screw in or out until drive roll

groove lines up with wire guide.
Close pressure roll assembly.
Only bottom drive roll alignment is

adjustable. Turn adjustment screw
in or out until groove in drive roll
lines up with wire guide as shown.

Cleaning Drive Rolls:

Remove drive rolls, and clean
grooves using a wire brush.

Correct

8

7

6

OM-269631 Page 30

Aligning Wire Guide And Drive Rolls

Incorrect

9

10

Tools Needed:

3/16 in.

250 764-A

5-17. Connecting Welding Gun

5

1

Gun Locking Tab In Place

! Turn Off wire feeder and

welding power source.

1 Gun Securing Knob
2 Gun Block

2

5

3 Gun Power Pin
4 Power Pin Groove
5 Gun Locking Tab
Loosen knob, insert gun end into

block. Position power pin as
close as possible to drive rolls
without touching. Align the gun
power pin groove with the gun
locking tab. Tighten knob.

6 Gun Trigger Plug
7 Gun Trigger Receptacle
Connect gun trigger plug to gun

trigger receptacle.

Internal Side View

Gun Locking Tab Out Of Place

4

3

6

7

246 100 / Ref. 270 080-A

OM-269631 Page 31

5-18. Connecting Shielding Gas

3

4

2

Rear View

1 Gas Hose With 5/8-18

Right-hand Thread Fittings

2 Shielding Gas Cylinder

. Shielding gas pressure not to

exceed 90 psi (620 kPa).

3 Valve
4 Flowmeter
Close valve on cylinder when fin-

ished welding.
Items 1−4 are user supplied.

Tools Needed:

5/8 in.

1

5-19. Connecting Weld Cable And Work Sense Lead

From
Wire
Feeder

4

1

3

2

250 767-A

1 User Supplied Weld Cable
Follow wire manufacturer’s recom-

mendations for weld cable polarity.
2 Male Connector
3 User Supplied Female

Connector

Push female connector over male
connector, and turn 1/4 turn clock­wise.

4 Work Sense Lead
Connect work sense lead to termin-

al on rear of feeder.

OM-269631 Page 32

250 768-A

5-20. Installing And Threading Welding Wire

. Hold wire tightly

to keep it from
unraveling.

3

Installing Wire And Adjusting
Hub Tension:

1 Retaining Nut
2 Hub Tension Adjustment

Screw

Remove retaining ring, and install
spool so hub pin fits spool hole. Re­install retaining nut.

Adjust tension nut so only a slight
force is needed to turn spool.

Threading Welding Wire:

3 Pressure Assembly

Adjustment Knob
Lay gun cable out straight.
Open pressure assembly, hold wire

tightly, and cut off end. Push wire
through guides into gun.

Close and tighten pressure assem­bly. Press Jog switch until wire
comes out gun.

Feed wire against wooden surface,
and tighten knob so wire does not
slip.

Cut off wire, and close door.

WOOD

1

Pull and hold wire; cut off end.

Tighten

Clockwise

2

6 in.

(150 mm)

Tools Needed:

Ref. 250 764-A

OM-269631 Page 33

SECTION 6 − OPERATION

6-1. Operational Terms

The following is a list of terms and their definitions as they apply to this interface unit:

General Terms:
Amps Indicates average amperage while welding and holds the value for 10 seconds at end of weld.
Arc Control The adjustment of arc cone width and arc characteristics in the SS FCAW, MIG and RMD processes.

CO

2

C20-C25 Gas mixture of mainly Argon and 20-25% CO
Dual Schedule A two position switch which attaches to (or incorporated in) the gun handle that can be used to change weld

EXX10 Stick welding electrode type. EXXX1 or EXXX2 are typically used on this setting (cellulosic electrode).
EXX16/EXX18 Stick welding electrode type. EXXX3 through EXXX8, or stainless are typically used on this setting (low

FCAW (Flux Cored Arc
Welding)

Hot Start Increases output amperage at start of weld. This helps eliminate electrode sticking during arc initiation.
Jog Method for feeding wire without contactor or gas valve being energized.
Metal Core MIG wire consumable = carbon metalcore.
MIG (GMAW) Also referred to as solid wire welding. An arc welding process which joins metals by heating them with an arc.

Preflow The time that the shielding gas flows prior to an arc start.
Postflow The time that the shielding gas continues to flow after the arc has been terminated.
Process A selection made for MIG, RMD, Stick, or Flux Core (FCAW).
Purge Method for energizing the gas valve(s) to purge gas lines before welding and to preset gas pressure at the regu-

Increasing Arc Control value increases the arc cone width and subsequently effects the arc length (end of
electrode to workpiece).

100% CO2 shielding gas.

2.

parameters during the MIG welding processes. The gun trigger operates as a standard trigger. Dual Schedule is
always activated.

hydrogen type electrode).
Flux cored arc welding is a continuous electrode that is fed into the arc and depends on shielding gas from

either an external source or is generated from the decomposition of gas forming ingredients contained in the
electrode’s core.

The arc is between a continuously fed filler metal (consumable) electrode and the workpiece. Externally
supplied gas or gas mixtures provide shielding.

lator.

RMD RMD stands for Regulated Metal Deposition, a precisely controlled short-circuit transfer process. Benefits of

Solid MIG wire consumable = carbon solid.

Stick (SMAW) Stick (SMAW) welding uses a flux covered consumable electrode that produces a shielding gas and slag to

Synergic Synergic refers to the unit’s ability to use preprogrammed parameters to determine the actual pulse settings of

Trigger Hold This feature reduces welder fatigue by allowing continuous welding without holding the trigger.
Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 10 seconds hold value at end of weld.
Wire Selection of wire diameter for MIG and RMD processes. Wire diameter selections include 0.9, 1.0 and 1.2 mm.
WFS Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In

RMD are well suited to root pass welding on pipe, improves gap filling and spatter reduction. Provides less heat
input into the workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge materials.
Settings for RMD include Arc Length, Wire Speed and Arc Control.

shield the arc and molten weld puddle.

Peak Amperage, Background Amperage, Pulse Frequency, and Pulse Width at any specific wire feed speed
setting. This is a characteristic used in RMD processes.

Pulse and RMD, adjusting wire feed speed also increases power level on wire electrode (one knob control).

OM-269631 Page 34

6-2. CE Welding Power Source Controls

32

5

9

6

7

8

41

269 545-A

1 Stick Process Select Button
2 AMPS Display
3 Amperage Adjustment Knob

4 Feeder Select Button
5 Memory Card Program Save Button
6 Memory Card Program Load Button

7 Memory Card In Use Indicator Light
8 Electrode Select Button
9 Memory Card Busy Indicator Light

The memory card slot uses an SD
memory card.
SD Logo is a trademark of the SD−3C,
LLC.

OM-269631 Page 35

6-3. Welding Power Source Operation Description

Stick Process Select
Button

Adjustable DIG Press STICK button for two seconds to enter the adjustable DIG mode. The amperage display will show the

Press and release this button to activate the stick welding process controls. The STICK text below the button
illuminates as well as the active stick electrode type text and the swoosh above the amperage adjustment knob.
The operator must select the desired stick electrode type and adjust the amperage knob to the appropriate
setting within a range from 40 to 350 amps.

DIG setting with the right most decimal point illuminated. DIG can be adjusted over a range of 0 to 99 with 40
as the default. Setting for EXX10 and EXX16/EXX18 are independent (each has its own DIG setting).
Pressing any button exits the DIG adjustment mode.

. DIG can be adjusted while welding.

Adjustable Hot Start When in the Adjustable DIG mode, press the STICK button to enter the adjustable Hot Start mode. The

AMPS Display This display shows the amperage setting. The average amperage is displayed while welding and continues to

Amperage Adjustment
Knob

Feeder Select Button Press and release the Feeder Button on the power source to activate weld processes from an attached wire

Memory Card Program
Save Button

Memory Card Program
Load Button

Memory Card In Use
Indicator Light

Electrode Select Button Press and release this button to select the desired stick electrode type (EXX10 or EXX16/EXX18). The text

Memory Card Busy
Indicator Light

amperage display will show the Hot Start setting. Hot Start can be adjusted over a range of 0.0 to 2.0 with

1.0 as the default. The higher the number, the longer hot start takes to ramp down to the welding amperage
set on the unit.

appear for 10 seconds after the welding arc is extinguished.
Use this knob to set a desired amperage setting for the stick welding process. Rotating the knob clockwise

increases amperage and counter−clockwise decreases amperage. Amperage adjustment is active when the
swoosh above the knob is illuminated. If a remote control is connected to the Remote 14 receptacle, the unit will
automatically adjust output control to a primary/secondary configuration. In this configuration, the Amperage
Adjustment knob on the unit becomes the primary and sets the maximum amperage output of the unit. The
remote control becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage
Adjustment knob setting.

feeder. The FEEDER text below the button illuminates. Refer to the feeder operation section.
Press and release this button to save all stored operator settings as a setup configuration file to the memory

card. The busy LED will illuminate to indicate the save operation is in progress. In addition, whenever the SAVE
button is pressed a file named SUMMARY is updated on the MEMORY Card. This file has a Status Summary,
Firmware Revisions, and Fault History. The file can be read using a computer equipped with a memory card
reader. This information can be used for maintenance schedules or troubleshooting.

Press and release this button to load a previously saved configuration file from the memory card in the card slot.
This operation allows restoring previously saved operation settings on the card to a different system. The busy
LED will illuminate to indicate the load operation is in progress.

The memory CARD text will illuminate when custom MIG or RMD type weld process data is currently being
used from the memory card.

above or below the button will illuminate for the active electrode type. This button is only active with the stick
welding process selection and only then will text for the electrode type selection illuminate

The memory card busy LED illuminates during the following conditions: storage/retrieval of operator settings,
usage of custom MIG type weld process, and software upgrades.

OM-269631 Page 36

6-4. Memory Card Slot

1 Memory Card Slot

1

A. Description

Memory Card Slot This is the memory card slot. A memory card can be inserted into the slot and used for storing and retrieving

operator settings, providing custom MIG type weld process data, and loading software updates to the unit. If the
power source has multiple users, each user may use a card to store and load their own personal settings. Push
in and release the card edge to eject it from the slot.

B. Using Optional Memory Card

Memory Card Insertion Lift and hold memory card access cover open. Insert memory card into slot, push card all the way into the slot,

Optional Program Card
Operation

and then release. Close the memory card access cover
Insert the optional program card into the slot. Select wire feeder by pressing the FEEDER button on the power

source. Select the weld process by pressing the MIG PROCESS button on the feeder front panel until the
desired process is illuminated. The memory CARD text will illuminate on the power source front panel as well as
on the feeder front panel to indicate that the optional program is being used from the memory card. If applicable,
select the wire diameter by pressing the MIG Wire button on the feeder front panel until the desired wire
diameter is illuminated. Remove the memory card to revert to standard operation.

. Some optional program cards only support a single wire diameter, in this case, only that diameter will

illuminate.

Software Update Card
(System Software Update)

Insert the software update card into the slot. Perform software update by pressing and holding the LOAD button
on the power source front panel until ”UPd” appears on the 7−segment LED display. Wait fo the software update
to complete (approximately two minutes). Remove card.

. During the software update, the displays on both the power source and feeder front panels may dis

play “H99” or "H98" as well as the "UPd" or go blank for a period of time. This is normal during a software up
date. Do not remove the memory card until the software update has completed. Do not turn off the power
source until the software update has completed.

OM-269631 Page 37

6-5. Feeder Units Switch

1 Feeder Units Switch
Switch position up for inches per

minute.
Switch position down for meters per

1

minute.

Notes

Ref. 250 764-A

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-269631 Page 38

6-6. PipePro XC RMD Feeder Front Panel Controls

1

14

2

4

6

7

3

5

8

9

10

13

1 Power Control Button
2 Volts/Arc Length Display
3 Wirespeed/Amps Display
4 Volts/Arc Length Adjustment Knob

5 Wirespeed Adjustment Knob
6 Purge Button
7 Arc Control Button
8 Trigger Hold Button
9 Jog Button

11

12

269 634-A

10 FCAW Process Select Button
11 MIG Process Select Button
12 Wire Diameter Select Button
13 Memory Card Indicator Light
14 Accu-Power Indicator Light

OM-269631 Page 39

6-7. PipePro XC RMD Feeder CE Operation Description

Power Control Button Press this button to power up or power down the wire feeder. When powered down, the feeder is still in a

Volts/Arc Length Display This display shows the voltage setting for MIG, Gas-Shielded and Self-Shielded processes (10.0 to 39.0 volts)

Wirespeed/Amps Display This display shows the wire speed setting within the range based on the MIG process selected (see Table 6-1).

Voltage/Arc Length
Adjustment Knob

Wirespeed Adjustment
Knob

Purge Button Press and hold this button to purge shielding gas lines prior to welding or to preset gas pressure at the regulator.

Timed Purge Pressing and releasing the purge and trigger hold buttons simultaneously will activate the timed purge

Arc Control Button Press and release this button to adjust arc control. When in a FCAW process (gas-shielded or self-shielded) or

standby mode allowing it to power up when the power control button is pressed. When in the standby mode, a
decimal point will flash in the lower right corner of the wire speed display.

and it shows the arc length for the RMD process (−3.0 to +3.0 in 0.1 increments with 0 as nominal). “VOLTS”
will be illuminated below the display when showing voltage. “ARC LENGTH” will be illuminated when showing
arc length. The actual voltage is displayed while welding and continues to appear for 10 seconds after the weld­ing arc is extinguished.

When showing wire speed, “WIRESPEED” will be illuminated below the display. While welding, the display will
show weld amperage and “AMPS” will be illuminated below the display. Measured amperage just prior to the
end of the welding operation will appear in the display for 10 seconds after the welding operation. The display
will then revert back to wire speed.

Use this knob to adjust the desired voltage setting (10.0 to 39.0 volts) or arc length setting (−3.0 to +3.0 in 0.1
increments with 0 as nominal) depending on the type of MIG process selected. Rotating the knob clockwise
increases the voltage and counter-clockwise decreases the voltage. Voltage/arc length adjustment is active
when the swoosh above the knob is illuminated.

Use this knob to adjust wire speed within the range based on the MIG process selected (see Table 6-1). Rotat­ing the knob clockwise increases the wire speed and counter-clockwise decreases the wire speed. Wire speed
adjustment is active when the swoosh above the knob is illuminated.

Release the button to stop the purge operation.

function. The volts/arc length display will count down in 1 second decrements starting at the preset amount
of time. A default preset time period is set at 30 seconds, but the time can be changed within a range of 5 to
60 seconds using the volts/arc length adjust knob. Rotating the knob clockwise increases time and
counter-clockwise decreases time. The volts/arc length display will show the set time after making any
desired adjustment. If no further changes are made to the time period, after one second the unit will resume
the count down display.

short circuit MIG process, the volts display will show the setting and the wire speed display will show “Ind”. Ro­tating the volts knob clockwise increases the arc control and counter-clockwise decreases the arc control. The
adjustable range is 0 to 99. For a FCAW process the default is 50. For a short circuit MIG process the default
setting is 25.

When in an RMD process, the volts display will show the setting and the wire speed display will show “Arc”.
Rotating the volts knob clockwise increases the arc control and counter-clockwise decreases the arc control.
Pressing any button exits the arc control adjustment feature.

. When using dual schedule, arc control settings for each dual schedule switch position are independ-

ent (each switch position has its own arc control setting). Arc control can be adjusted while welding

Trigger Hold Button Press and release this button to enable/disable the trigger hold feature. The LED will illuminate above this button

Jog Button Press and hold this button to jog wire from the feeder. Rotate the wire speed adjustment knob to change the jog

Auto-Jog Pressing and releasing the jog and trigger hold buttons simultaneously will activate the auto jog function.

to indicate when trigger hold is active. When trigger hold is active, the gun trigger must be pressed and held
after the arc is established for a minimum of one half second, but not more than six seconds. Releasing the gun
trigger activates the trigger hold function. To stop welding, press and release the gun trigger.

speed within a range of 1.3 to 12.7 meters per minute (50 to 500 inches per minute). Rotating the knob clock­wise increases jog speed and counter-clockwise decreases job speed. Release the button to stop the jog oper­ation and the display will return to the initial wire speed setting. The default setting is 12.7 meters per minute
(500 inches per minute).

This feature will automatically jog a preset amount of wire. The volts display will count down to 0.01 meter
(0.1 feet) decrements starting at the preset wire length. A default preset wire length is set at 3.0 meters
(10.0 feet), but the length can be changed within a range of 1.5 to 9.1 meters (5.0 to 30.0 feet) using the
volts adjust knob. Rotating the knob clockwise increases wire length and counter-clockwise decreases wire
length. The volts display will show the set wire length for a short time after making any desired adjustment.
If no further changes are made to the wire length, after one second the unit will resume the countdown dis­play. Jog speed can also be adjusted within a range of 1.3 to 12.7 meters per minute (50 to 500 inches per
minute) using the wire feed speed adjust knob and the wire feed speed display will show the current job
speed setting.

OM-269631 Page 40

6-7. PipePro XC RMD Feeder Operation Description (Continued)

FCAW Process Select
Button

MIG Process Select
Button

Wire Diameter Select
Button

Memory Card Indicator
Light

Accu-Power Indicator
Light

Pre/Post Flow Pressing and releasing the arc control and purge buttons simultaneously will activate the adjustable preflow and

Press this button to select the desired FCAW process. Possible selections include “NO GAS” (self-shielded
FCAW) or “GAS” (gas-shielded FCAW). The process type text will illuminate to show the active process.

Press this button to select the desired short circuit MIG process. Possible selections include MIG, RMD METAL
CORE, RMD SOLID C15−C25, RMD Solid 100% CO2. The process type text will illuminate to show the selec­ted wire diameter.

Press this button to select the electrode diameter used for the selected MIG process. Possible selections in­clude 0.9 mm, 1.0 mm and 1.2 mm. The wire diameter text will illuminate to show the selected wire diameter.

“CARD” will illuminate when a memory card with a custom weld program is inserted into the power source card
reader slot.

“ACCU−POWER” will illuminate when the Accu-Power feature is enabled on the system.

postflow function. When this occurs, the volts display will show “PrE” and the wire speed display will show a
time setting in 0.1 seconds increments. Adjustment of the preflow time is made by turning the wire speed knob.
Adjustable range is 0 to 5 seconds in 0.1 second increments.

Turning the voltage knob clockwise will access adjustable postflow. The voltage display will show “PSt” and the
wire speed meter will show a time setting in 1 second increments. Adjustment of the postflow time is made by
turning the wire speed knob. Adjustable range is 0 to 60 seconds in 1 second increments.

Table 6-1. FCAW And MIG Process Parameters

Process Wire Size (mm) WFS Range (mpm)

Self-Shielded FCAW Various 1.3−5.1

Gas-Shielded FCAW Various 1.3−12.7

0.9 1.3−12.7

MIG

RMD METAL CORE C20 GAS *1.2 1.9−5.7

RMD SOLID C15−C25

RMD SOLID 100% CO2

*This program is optimized for metal core wire.

1.0 1.3−12.7

1.2 1.3−12.7

0.9 2.5−8.9

1.0 2.5−7.6

1.2 1.9−6.4

0.9 3.8−6.4

1.0 3.8−6.4

1.2 2.5−5.1

Notes

OM-269631 Page 41

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect power before maintaining.

n = Check ~ = Clean l = Replace

Every
3
Months

l Unreadable Labels ~ Weld Terminals nl Weld Cable l Cracked Parts

n 14-Pin Cord n Gas Hose and Fittings n Gun Cable

Every
6
Months

l Cracked Electrode
Holder Parts

Or

~ Inside Unit ~ Drive Rolls

nl Gun Cables

7-2. 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.

OM-269631 Page 42

Ref. 250 702-B

7-3. Cleaning Debris From Shielding Gas Filter Fitting

Rear View of Feeder

1

FILT

! Disconnect power before

maintaining.

1 Shielding Gas Filter Fitting
Remove fitting from gas valve on

back panel of feeder.
Blow compressed air through the

threaded male end of fitting to dis­lodge debris from internal mesh
screen.

. Replace fitting if blowing com-

pressed air through fitting does
not clear obstructions.

Reinstall fitting into gas valve.
Tighten fitting to 200 in. lbs (22.6 N⋅m).

Tools Needed:

3/4 in.

Notes

Ref. 804 004-A / 805 128-A

OM-269631 Page 43

7-4. Restoring Factory Defaults

Full System

A full factory reset can be accomplished by pressing STICK and FEEDER buttons on the power source simultaneously for more than four seconds. The
display will show “rSt” and then go to dashes when the reset is complete.

7-5. Viewing Software Revision

Pressing the EXX10, EXX16/EXX18 and a hidden button about 1 inch below the FEEDER button on the power source simultaneously will display the
Software Revision.

7-6. Power Source Calibration Procedure

Only qualified persons should install, operate, maintain, and repair this unit.

1. Calibrated DC voltmeter and clamp-on DC ammeter (e.g. Fluke 337)

2. Calibration Card

3. Shorting cable (2/0)

1. Disconnect cables from all output studs.

2. Turn on power to the welding system.

3. Insert Calibration card.

a. Lift and hold memory card access cover open.

b. Insert memory card into slot (push card all the way into slot and then release).

c. Close memory card access cover.

d. Power source will display CAL.

4. Calibrate voltage as follows:

a. Connect voltmeter from + stud to − stud.

b. Press FEEDER button on the power source front panel. Open circuit voltage should now be present from + stud to the − stud.

c. Using the knob on the power source front panel, set the display voltage to the measured value on the voltmeter.

d. Press FEEDER button on the power source front panel to end the voltage calibration.

e. Power source will display CAL.

5. Calibrate amperage as follows:

a. Connect shorting cable from + stud to − stud.

b. Attach clamp-on ammeter around shorting cable.

c. Press STICK button on the power source front panel. Amperage should now be flowing in the shorting cable.

d. Using the knob on the power source front panel, set the display amperage to the measured value on the ammeter.

e. Press STICK button on the power source front panel to end the amperage calibration.

f. Power source will display CAL.

g. Disconnect shorting cable.

6. Remove Calibration card as follows:

a. Lift and hold memory card access cover open.

b. Push in and release memory card to eject card.

c. Grasp memory card and remove from slot.

d. Close memory card access cover.

7. Turn off power to the welding system.

OM-269631 Page 44

7-7. Removing Right Side Panel and Measuring Input Capacitor Voltage

! Turn Off welding power

source, and disconnect
input power.

! Significant DC voltage can

remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.

! Only qualified persons

should install, operate,

1

2

3

maintain, and repair this
unit.

Turn Off welding power source, and
disconnect input power.

1 Right Side Panel
To remove panel, remove screws

securing panel to unit.
2 Relinking Board PC10
3 Voltmeter
Measure the dc voltage across the

screw terminals on PC10 as shown
until voltage drops to near 0 (zero)
volts.

. If the capacitor voltage does

not drop to near zero after sev­eral minutes, use a bleeder re-

4

Typical Bleeder Resistor

25 to 1000 ohms,
5 watt resistor

+ lead to lower right terminal, −

lead to upper right terminal

sistor of between 25 and 1000
ohms, at least 5 watts, #16
AWG 1000 volts DC insulating
rating wire to discharge the ca­pacitor(s) .

4 Typical Bleeder Resistor
An example of a typical bleeder

resistor is shown on this page.
Proceed with job inside unit. Reinstall

right side panel when finished.

Tools Needed:

5/16 in.

#16 AWG 1000 volts DC

insulation rating, approx

3 in. (76 mm) leads

Ref. 250 702-B / 269 652-A

OM-269631 Page 45

7-8. Welding Power Source And Feeder Diagnostic Help Codes

H1

Display Code Fault Description

H01 Primary Power Circuit Over Current Indicates a malfunction in the primary power circuit. If this code

H02 Temperature Sensor Malfunction Indicates thermal protection circuitry is malfunctioning. If this

H03 Secondary Circuit Over Temperature Indicates left side of unit has overheated. Unit has shutdown to

H05 Primary Circuit Over Temperature Indicates right side of unit has overheated. Unit has shutdown

H08 Output Over Voltage Malfunction Indicates secondary power circuit is malfunctioning. If this code

H09 Primary Power Circuit Current Detect Malfunction Indicates primary power circuit is malfunctioning. If this code

H10 Primary Power Circuit Control Malfunction Indicates primary power circuit is malfunctioning. If this code

H11 Primary Bus Capacitor Voltage Imbalance Indicates primary power circuit is malfunctioning. If this code

H12 Primary Input Line Voltage Malfunction Indicates input primary line voltage is too low or power source

H13 Voltage Sense System cannot measure output voltage. Make sure work sense

H25 Duty Cycle Indicates duty cycle limit exceeded. Output stops and the cooling

H26 Button Stuck Power Source Indicates button is stuck on the power source upon start up.

H31 Stuck Contactor Stick Indicates stuck remote contactor in Stick mode. Fault will clear

H40 Tach Indicates tach error. Check feeder drive housing and wire spool for

H42 Motor Indicates motor error. Check feeder drive housing and wire

H44 Motor Low Bus Indicates input primary line voltage is too low or power source

H45 Button Stuck Feeder Indicates button is stuck on the feeder upon feeder power up.

0

Display Example

appears on the display, contact the nearest Factory Authorized
Service Agent.

code appears on the display, contact the nearest Factory
Authorized Service Agent.

allow fans to lower left side temperature. Operation will continue
after unit is within normal temperature range.

to allow fans to lower right side temperature. Operation will
continue after unit is within normal temperature range.

appears on the display, contact the nearest Factory Authorized
Service Agent.

appears on the display, contact the nearest Factory Authorized
Service Agent.

appears on the display, contact the nearest Factory Authorized
Service Agent.

appears on the display, contact the nearest Factory Authorized
Service Agent.

is incorrectly linked.
Increase primary line voltage to at least 90% of specified
nominal voltage.

lead is connected between feeder and work. If this code
continues to appear on the display, contact the nearest Factory
Authorized Service Agent.

fan will run. Wait 15 minutes for unit to cool. Reduce amperage,
voltage, wire feed speed, or duty cycle before welding.

Fault will clear when button is released.

when foot pedal or control device contactor is released.

obstructions. If this code continues to appear on the display, con­tact the nearest Factory Authorized Service Agent.

spool for obstructions. If this code continues to appear on the
display, contact the nearest Factory Authorized Service Agent.

is incorrectly linked.
Increase primary line voltage to at least 90% of specified
nominal voltage.
If this code continues to appear on the display, contact the
nearest Factory Authorized Service Agent.

Fault will clear when button is released.

OM-269631 Page 46

7-8. Welding Power Source And Feeder Diagnostic Help Codes (Continued)

H46 Trigger Stuck Indicates trigger stuck fault. Fault will clear when trigger is re-

H48 Trigger Fault Indicates trigger was held too long in trigger jog (the lesser of

H60 Memory Card Fault Indicates unable to read memory card. Faulty memory card or

H61 File Read Error Indicates faulty file on memory card.
H62 File Write Error Indicates full or faulty memory card.
H63 Invalid File Indicates an invalid file on memory card. The system was able

H64 Memory Card Locked Indicates a save was attempted to a locked card. This refers to

H65 Read Only File Indicates a save was attempted to a file that has been marked

H66 No Memory Card Detected Indicates no memory card detected when a memory card oper-

H67 Unsupported Memory Card Format Indicates that a memory card with an unsupported format was

H70 Weld Library Indicates missing/incomplete weld library in power source.

H98 Serial Communication Loss Indicates serial communication was initially made and is now

H99 Serial Communication Malfunction Indicates serial communication is malfunctioning. Check wire

leased.

60 seconds or 30 ft (9.1 m) of wire.

wrong format.

to read the file; however, the contents of the file were invalid.
Remove card or press any button to clear error.

the physical switch on the memory card. Unlock the memory
card and try again. Try a different memory card. Remove card
or press any button to clear error. If this code continues to ap­pear on the display, contact the nearest Factory Authorized
Service Agent.

read-only. Check with the appropriate person to see if the attrib­utes are read only for a reason (the attributes can be altered
using a PC). Use a different card. Remove card or press any
button to clear error.

ation was attempted. Insert a card or press any button to clear
error. Try a different memory card. If this code continues to
appear on the display, contact the nearest Factory Authorized
Service Agent.

detected. Reformat card, or try a different memory card.

Weld library must be loaded from memory card.

malfunctioning. Check wire feeder/power source control cable
connection and tighten if necessary. May appear normally dur­ing firmware updates. If this code continues to appear on the
display, contact the nearest Factory Authorized Service Agent.

feeder/power source control cable connection and tighten if
necessary. May appear normally during firmware updates. If
this code continues to appear on the display, contact the
nearest Factory Authorized Service Agent.

OM-269631 Page 47

7-9. Troubleshooting Welding Power Source/Wire Feeder Issues

If the welding power source and wire feeder are NOT responding after everything is connected, follow the items listed below before contacting the
nearest factory-authorized service agent:

Welding power source is plugged in and there is no power after turning on unit.

S If unit is directly connected to a line disconnect box or plugged into a receptacle from a line disconnect box, be sure that the line disconnect switch

or main breaker is in the ON position.

Wire does not feed from wire feeder to end of gun.

S Check to see if wire diameter matches the groove size of the drive rolls.

S Check if tension on drive rolls is too loose or too tight.
S Check if gun liner is the correct size for the wire size.
S Check if contact tip is correct size for the wire size, and that end of contact tip is not plugged.
S Check if gun end is fully inserted into wire drive housing at feeder, and knob is tightened down to secure gun end.
S Ensure gun cable is not coiled.

Weld is not consistent from one welding application to another.

S Be sure that work clamp is connected to a clean, paint-free area of pipe; otherwise, grind an area if necessary to make a good work connection.
S Keep work clamp as close as possible to joint being welded.
S Check if work sense lead is connected to the feeder, and that work connection is secure. Check for any frayed wires at work end of work sense

lead that may prevent a good connection.

S Be sure that work sense lead is separated from weld cables.
S Be sure gun angle during welding is straight in to 15 degrees back at joint.
S Follow recommended settings in Operation section of manual to select a starting point for welding.
S Recommended joint preparation and fit-up is 1/32-1/16 in (0.8-1.6 mm) land and a 1/8 in (3.2 mm) root opening.

Porosity in weld bead.

S Check shielding gas supply that there is enough gas and supply is turned on.
S Check shielding gas flow rate at regulator.
S Check that gas pressure to the wire feeder does not exceed 90 psi (621 kPa).
S Check all shielding gas fitting and tighten if necessary.
S Remove gun end from wire drive housing and check condition of O-rings. Replace any worn or missing O-rings.
S Check power pin end of gun and tighten with a wrench.
S Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end.
S Check and clean shielding gas nozzle on gun.
S Shield joint from wind.

Trouble feeding wire when welding. Check drive rolls and wire guides to make sure they match the wire style
and size.

S Check drive roll tension and readjust if necessary.
S Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end.
S Check if hub tension at wire spool is too tight or too loose and readjust if necessary.
S Be sure that welding gun cable is as straight as possible from wire feeder to workpiece.
S Check if contact tip is correct size for the wire size, and that end of contact tip is not plugged.
S Check if gun liner is the correct size for the wire size and liner is not dirty or damaged. Clean or replace gun liner if necessary.

OM-269631 Page 48

7-10. Welding Power Source Troubleshooting

Trouble Remedy

No weld output; unit completely in­operative.

No weld output; meter display On. Check, repair, or replace remote control.

Place line disconnect switch in On position (see Section 5-11).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11).

Check for proper input power connections (see Section 5-11).

Unit overheated. Allow unit to cool with fan On.

Check voltmeter/ammeter Help displays.

Erratic or improper weld output.

No 24 volts AC output at Remote 14
Feeder receptacle.

When remote control is connected to
unit output is always on.

Use proper size and type of weld cable (see Section 5-9).

Clean and tighten all weld connections.

Check work sense lead. Straighten any coiled cables.

Reset supplementary protector CB2.

Check remote control switch and potentiometer resistances.

7-11. Wire Feeder Troubleshooting

Trouble Remedy

Wire feeds, shielding gas flows, but
electrode wire is not energized.

Wire feeder is on, display does not light
up, motor does not run, gas valve and
welding power source contactor do not
pull in.

Electrode wire feeding stops, or feeds
erratically during welding.

Check cable connections. Check cables for continuity, and repair or replace cables if necessary.

Check and reset circuit breaker at welding power source.

Check gun trigger connection. See gun Owner’s Manual.

Check gun trigger. See gun Owner’s Manual.

! Disconnect power before troubleshooting.

Readjust hub tension and drive roll pressure.

Change to correct size drive roll (see Table 9-1).

Clean or replace dirty or worn drive roll.

Incorrect size or worn wire guides.

Replace contact tip or liner. See gun Owner’s Manual.

Remove weld spatter or foreign matter from around nozzle opening.

Have Factory Authorized Service Agency check drive motor or motor control board PC1.

Motor runs slowly. Check for correct input voltage.

Wire feeder displays light up, feeder
jogs, purges, but unit is inoperative.

When triggered, wire feeds but no gas,
no contactor.

Check welding gun trigger leads for continuity, and repair leads or replace gun.

If the welding arc does not establish in 2 seconds after the gun trigger is activated the unit will feed
wire, but turns off contactor and gas valve. If the gun trigger is still activated after 60 seconds or 30 ft
(9.1 m) of wire was fed from the gun, the wire will stop feeding.

OM-269631 Page 49

SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram For CE Welding Power Source

OM-269631 Page 50

269 637-D

OM-269631 Page 51

Figure 8-2. Circuit Diagram For XC RMD Wire Feeder CE

OM-269631 Page 52

269 639-A

OM-269631 Page 53

29

SECTION 9 − PARTS LIST

. Hardware is common and

7

8

9

31

6

27

18

17

3

5

28

22

25

13

14

11

34

33

35

36

2

37

21

20

not available unless listed.

19

24

16

15

23

30

32

1

26

12

10

269 788-A

4

Figure 9-1. Main Assembly

OM-269631 Page 54

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 9-1. Main Assembly

1 See Figure 9-2 Base Assy 1... ..... . .........................................................

2 See Figure 9-3 Windtunnel, LH w/Cmpnts 1... ..... . ............................................

3 See Figure 9-3 Windtunnel, RH w/Cmpnts 1... ..... . ...........................................

4 See Figure 9-4 Front Panel Assy 1... ..... . ...................................................

5 269201 Rear Panel 1... .......... .. .........................................................

6 See Figure 9-5 Bracket Assy, Control Boards 1... ..... . .........................................

7 249848 Handle, Rubberized Carrying 2... .......... .. .........................................

8 187234 Cover, Top 1... .......... .. .........................................................

9 249881 Panel, Side LH 1... .......... .. .....................................................

10 249882 Panel, Side RH 1... .......... .. .....................................................

11 206270 Insulator, Side 1... .......... .. ......................................................

12 234271 Sheet, Insulator Side Panel 1... .......... .. ..........................................

13 203310 Insulator, Switch Power 1... .......... .. ..............................................

14 S1 244920 Switch, Tgl 3PST 40A 600VAC SCR Term Wide Tgl 1... .... .. .. .....................

15 FM1 222728 Fan, Muffin 24VDC 3000 RPM 255 CFM 6.378 Mtg Holes 1... ... .. .. ...............

16 255287 Shroud, Fan 1... .......... .. ........................................................

17 T1 269567 Xfmr, HF 380/400 Unit 1... .... .. .. ...............................................

18 T2 269675 Xfmr, Control E&I 380V W/23V & 34V CT 415VA 1... .... .. .. ........................

19 C1,C2 230273 Capacitor, Polyp Film .5 UF 1000 VRMS 10% 2... .. . .. .........................

20 C3,C4,... ..

C5,C6 234104 Capacitor, Elctlt 2700 UF 450 VDC Can 2.52 Dia 4. .. .......................

21 233489 Bracket, Capacitor Support 1... .......... .. ...........................................

22 183827 Bus Bar, Output 1... .......... .. ....................................................

23 185214 Bus Bar, Interconnecting 1... .......... .. .............................................

24 185992 Bus Bar, Capacitor 2... .......... .. ..................................................

25 199840 Bus Bar, Diode 4... .......... .. .....................................................

26 PC4 231559 Circuit Card Assy, Interconnecting 1... ... .. .. .....................................

27 CB2 083432 Supplementary Pro, Man Reset 1P 10A 250VAC Frict 1... ... .. .. ...................

28 265787 Capacitor Module 1... .......... .. ...................................................

29 L6 241027 Core, Toroidal .748 Id X 1.142 Od X .600 Thk 1... .... .. .. ...........................

30 L5 255735 Core, Toroidal .900 Id X 1.400 Od X .500 Thk 2... .... .. .. ...........................

31 L7 255736 Core, Ferrite EMI Snap−On .393Id X .877Od X 1.290L 1... .... .. .. ...................

32 L8 185208 Choke, Common Mode 1... .... .. .. ..............................................

33 PC13 231563 Circuit Card Assy, Input Filter (R) 1... .. . .. .....................................

34 145743 Lug, Univ W/Scr 600V 2−14 Wire .250 Stud 7... .......... .. ............................

35 083147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High 2... .......... .. ....................

36 269696 Bracket, Mtg Standoff Filter Board Pipepro Xc (CE) 1... .......... .. ......................

37 269695 Bracket, Mtg Filter Board Pipepro Xc (CE) 1... .......... .. ..............................

Quantity

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-269631 Page 55

. Hardware is common and

not available unless listed.

2

6

3

1

5

4

269 788-A

Figure 9-2. Base Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 9-2. Base Assembly

1 250139 Base 1... .......... .. ..............................................................

2 L3,L4 250374 Inductor, DI−DT 2... .. . .. .....................................................

3 218566 Gasket, Inductor Mounting E70 Ferrite Core 2... .......... .. ...........................

4 250144 Bracket, Isolator 2... .......... .. ....................................................

5 250238 Mount, Vibration 50 Duro Flange Mtg 4... .......... .. ..................................

6 253523 Insulator, Output Inductor 1... .......... .. ............................................

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-269631 Page 56

. Hardware is common and

not available unless listed.

3

10

11

6

7

4

1

5

Item

No.

8

9

LH

RH

2

13

21

24

22

14

15

16

12

18

17

23

19

20

269 788-A

Figure 9-3. Windtunnel Assembly LH And RH

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 9-3. Windtunnel Assembly LH And RH

Windtunnel, LH w/Cmpnts 1........................... ............................................

1 179902 Windtunnel, LH 1... .......... .... ...................................................

2 204165 Heat Sink, Rect Dual Diode 1... .......... .... .........................................

3 D1,D2... ..

D3,D4 269909 Kit, Diode Power Module 1.... ...........................................

4 R1,R2 232296 Resistor/Capacitor Assy 2... .. . .... ............................................

5 179826 Insulator, Rectifier 1... .......... .... .................................................

6 181853 Insulator, Screw 4... .......... .... ...................................................

7 179276 Bushing, Snap−In Nyl 1.000 ID X 1.375 Mtg Hole Cent 2... .......... .... .................

8 010493 Bushing, Snap−In Nyl .625 ID X .875 Mtg Hole 1... .......... .... .......................

9 HD1 168829 Transducer, Current 1000A Module Max Open Loop 1... ... .. .... ...................

10 RT2 209223 Thermistor, NTC 30K ohm @ 25 Deg C 18.00 in Lead 1... ... .. .... ..................

11 C11−C14 180778 Capacitor Assy 4... . .... ...................................................

Windtunnel, RH w/Cmpnts 1........................... ...........................................

12 248750 Windtunnel, RH 1... .......... .... ...................................................

13 179930 Heat Sink, Power Module 1... .......... .... ..........................................

14 PM1,PM2**240144 Kit, Transistor IGBT Module 1... .... ........................................

15 SR1 249052 Kit, Diode Power Module 1... ... .. .... ...........................................

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
**This kit contains two modules and instructions. Be sure to follow the field kit instructions when performing the
installation.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-269631 Page 57

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 9-3. Windtunnel Assembly LH And RH (Continued)

16 RT1 173632 Thermistor, NTC 30K Ohm @ 25 Deg C 12.00In Lead 1... ... .. .... ...............

17 025248 Stand−Off, Insul .250−20 X 1.250 Lg X .437 Thd 4... .......... .... ......................

18 153403 Bushing, Snap−In Nyl .750 ID X 1.000 Mtg Hole Cent 2... .......... .... .................

19 CT1 181271 Xfmr, Current 500 Turn 1... ... .. .... ...........................................

20 177547 Bushing, Snap−In Nyl Ct−Mount 1.093 Mtg Hole 1... .......... .... .....................

21 L2 270446 Stabilizer, Output 1... .... .. .... ..................................................

22 L1 180026 Inductor, Input 1... .... .. .... ....................................................

23 W1 180270 Contactor, Def Prp 40A 3P 24VAC Coil w/Boxlug 1... ... .. .... .....................

24 181925 Insulator, Stabilizer Lead 1... .......... .... ...........................................

236287 Plugs, W/Leads (IGBT Gates) (Including) 1................ .... .............................

115091 Housing Plug+Skts (Service Kit) 1................. ..... ...................................

115094 Housing Plug+Skts (Service Kit) 1................. ..... ...................................

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-269631 Page 58

2

3

12

6

4

7

. Hardware is common and

not available unless listed.

13

5

11

9

10

15

1

14

8

269 788-A

Figure 9-4. Front Panel Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 9-4. Front Panel Assembly

1 248777 Panel Assy, Front 1... .......... .. ...................................................

2 234344 Bracket, SD Card Reader 1... .......... .. ............................................

3 236830 Door, SD Reader 1... .......... .. ...................................................

4 249764 Nameplate 1... .......... .. .........................................................

5 269545 Overlay, Front Interface UI 1... .......... .. ...........................................

6 213134 Knob, Encoder 1.670 Dia X .250 ID Push On w/Spring 1... .......... .. ...................

7 181245 Terminal, Pwr Output Red 1... .......... .. ............................................

8 182707 Terminal, Pwr Output Black 1... .......... .. ...........................................

9 180735 Washer, Output Stud 2... .......... .. ................................................

10 186621 Boot, Generic Output Stud 1... .......... .. ...........................................

11 181169 Spacer, Output Stud 2... ........... .. .................................................

12 PC12 244477 Circuit Card Assy, SD Card 1... .. . .. ...........................................

13 PC3 248006 Circuit Card Assy, UI w/ProgrAM PS 1... ... .. .. ...................................

14 PC5 267371 Circuit Card Assy, Feeder And Remote Interface 1... ... .. .. ........................

15 170391 Conn, Circ MS Protective Cap Size 20 Nylon 1... .......... .. ...........................

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-269631 Page 59

. Hardware is common and

not available unless listed.

3

2

6

4

7

1

5

269 788-A

Figure 9-5. Control Board Bracket Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Figure 9-5. Control Board Bracket Assembly

1 248768 Bracket, Mtg Circuit Cards 1... .......... .. ...........................................

2 PC2 258487 Circuit Card Assy, Inverter Control 400V Potted 1... ... .. .. .........................

3 PC1 248607 Circuit Card Assy, Process Control w/Program Potted 1... ... .. .. ....................

4 PC9 253621 Circuit Card Assy, VS Disconnect 1... ... .. .. .....................................

5 FM2 183918 Motor, Fan 24VDC 3000 RPM 43 CFM w/10 Ohm Resistor 1... ... .. .. ..............

6 083147 Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High 8... .......... .. ..................

7 198122 Stand−Off Support, PC Card .250 w/Post&Lock .500 3... .......... .. ....................

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-269631 Page 60

Description

Quantity

17

10

. Hardware is common and

not available unless listed.

19

21

6

16

14

5

18

4

8

22

20

3

23

15

13

7

11

9

12

29

2

52

48

47

50

55

49

54

51

46

30

45

28

26

27

31

25

32

53

44

35

43

37

38

39

40

36

41

40

24

42

34

33

1

Ref. 254 973-A

Figure 9-6. XC RMD Wire Feeder CE Assembly

OM-269631 Page 61

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 9-6. XC RMD Wire Feeder CE Assembly

1 248814 Case, Control Feeder Machined SC 12 Blk 1... .......... .. .............................

2 249160 Chassis, Control Box Suitcase 12 w/Stand−Off 1... .......... .. ..........................

3 M1 249057 Motor, Right Angle 23.6VDC 28:3:1 Gear Ratio 1... ... .. .. .........................

4 249056 Panel, Motor Mount 1... .......... .. .................................................

5 246453 Housing, Adapter Gun/Feeder 1... .......... .. ........................................

6 124778 Knob, T 2.000 Bar w/.312−18 Stud 1.000 Lg 1... .......... .. ............................

7 166071 Lever, Mtg Pressure Gear 1... .......... .. ............................................

8 079634 Pin, Hinge 1... .......... .. .........................................................

9 151828 Pin, Cotter Hair .042 X .750 1... .......... .. ..........................................

10 254959 Pin, Cotter Hair .062 X .375 1... .......... .. ..........................................

11 222100 Knob, Tension Adjust Assy w/Cupped Washer MM350 1... .......... .. ...................

12 222159 Spring, Torsion 1... .......... .. .....................................................

13 010224 Pin, Spring CS .187 X 1.000 1... .......... .. .........................................

14 234073 Pin, Hinge 1... .......... .. .........................................................

15 054263 Screw, Thumb Stl .250−20 X .500 Pld Type P 1... .......... .. .........................

16 237188 Lock, Pin Power 1... .......... .. ....................................................

17 234074 Clamp, Power Pin 1... .......... .. ...................................................

18 144172 Ftg, Hose Brs Barbed M 3/16 Tbg X .250−20 1... .......... .. ...........................

19 172076 Carrier, Drive Roll W/Components Keyed 24 Pitch 1... .......... .. .......................

20 605308 Ring, Rtng Ext .500 Shaft X .035 Thk 1... .......... .. .................................

21 079625 Washer, Wave .500 ID x 0.750 OD x.015t Stl Lbs 2... .......... .. .......................

22 092865 Key, Stl .1215/.1230 x .750 1... .......... .. ..........................................

23 248823 Insulator, Motor Suitcase 12 1... .......... .. .........................................

24 See Figure 9-7 Panel Assy, Front 1... ..... . ...................................................

25 249080 Cable Assy, Weld w/Strn Rel & Dinse 1... .......... .. ..................................

26 C1.C2 177360 Capacitor, Elctlt 20000 uf 45 VDC Can 1.40 Dia 2... .. . .. ......................

27 207678 Insulator, Capacitors 1... .......... .. ................................................

28 210133 Bracket, Capacitor Support SC12 1... .......... .. .....................................

29 SR1 035704 Rectifier, Integ Bridge 40. Amp 800V 1... ... .. .. .................................

30 248817 Insulator, Rear Panel 1... .......... .. ................................................

31 269638 Cable, Power 1... .......... .. .......................................................

131204 Housing Plug+Skts (Service Kit) 1................ .. ......................................

115094 Housing Plug+Skts (Service Kit) 1................. .. ......................................

32 239737 Receptacle, Banana Jack Blk 10−32 Binding Post 1... .......... .. .......................

33 249848 Handle, Rubberized Carrying 1... .......... .. .........................................

34 249062 Lift Eye 1... .......... .. ............................................................

35 248816 Shroud, Wire 1... .......... .. .......................................................

36 235608 Hub, Spool 12 Inch 1... .......... .. ..................................................

37 235607 Nut, Hub 1... .......... .. ...........................................................

38 237843 Knob, Brake Adjust (Diecast) 1... .......... .. .........................................

39 172918 Spring 1... .......... .. .............................................................

40 231211 Washer, Anti−Turn 2... ........... .. ..................................................

41 058424 Washer, FBR (Brake) 1... .......... .. ................................................

42 250514 Insulator, Spool Support 1... .......... .. .............................................

43 250455 Support, Spool 1... .......... .. .....................................................

44 250458 Stiffener, Case 1... .......... .. ......................................................

45 208076 Panel, Inner 1... .......... .. ........................................................

46 S1 217932 Switch, Rocker Spst .4VA .28VDC On-None-Off .187 Ter 1... .... .. .. .................

47 226819 Valve, 12VDC 1 Way .750−14 Thd 2mm Orf 100 Psi 1... .......... .. .....................

48 134834 Hose, Sae .187 Id X .410 Od Xcoil 1... .......... .. ....................................

49 220805 Nut, 750−14Nps 1.48Hex .41H Nyl 1... .......... .. ....................................

50 PC1 267325 Circuit Card Assy, Mtr Cntrl W/Prg Xc Fdr Potted CE 1... ... .. .. ....................

51 228165 Grommet, Scr No 8 Panel Hole .312 X .343 .515 High 4... .......... .. ...................

52 222181 Grommet, Scr No 8/10 Panel Hole .281 Sq .031 High 8... .......... .. ....................

53 234126 Nut, 1.000 Npt Knurled 1... .......... .. ..............................................

54 214860 Nut, Ln Pg21 1.26 Hex .14H Nickel Plated Brass 1... .......... .. ........................

55 211989 Fitting, W/Screen 1... ........... .. ...................................................

Quantity

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-269631 Page 62

Item

No.

Dia.

Mkgs.

Part

No.

079607 Kit, Drive Roll .045 VK−Gr 2 Roll 1................ .. ......................................

250071 Plugs, W/Leads (Front Interface) 1................ .. ......................................

250073 Plugs, W/Leads (Cap Bank) 1................ .. ..........................................

250075 Plugs, W/Leads (Volt Sense) 1................ .. .........................................

250077 Plugs, W/Leads (Dc Supply) 1................ .. ..........................................

250693 Plugs, W/Leads (Gas Valve) 1................ .. ..........................................

. Hardware is common and

not available unless listed.

Description

Figure 9-6. XC RMD Wire Feeder CE Assembly (Continued)

76

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

2

1

3

Figure 9-7. XC RMD Wire Feeder CE Front Panel

Description

4

5

254 974-A

Quantity

1 248745 Panel, Front w/Studs 1... .......... .. ................................................

2 269634 Nameplate 1... .......... .. .........................................................

3 248751 Nameplate 1... .......... .. .........................................................

4 174991 Knob, Pointer 1.250 Dia X .250 ID w/Spring Clip−.21 2... .......... .. ....................

5 250268 Cable, Trigger 18 In Dual Schedule 1... .......... .. ....................................

115093 Housing Plug+Skts (Service Kit) 1................. .. ......................................

080328 Rcpt w/Skts, Free Hanging 1................ .. ...........................................

6 PC2 248746 Circuit Card Assy, UI w/Program 1... ... .. .. ......................................

7 253556 Gasket, Front Pnl 1... .......... .. ...................................................

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Figure 9-7. XC RMD Wire Feeder CE Front Panel

OM-269631 Page 63

Notes

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2016

(Equipment with a serial number preface of MG or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective
date of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. 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, Miller will repair or replace
any warranted parts or components that fail due to such defects in
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed. If notification is submitted as an online warranty claim, the
claim must include a detailed description of the fault and the
troubleshooting steps taken to identify failed components and the
cause of their failure.

Miller 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 twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.

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
* Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/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
* Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* 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.)

* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)

* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

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) Torches
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns

Miller’s True Blue® 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 Miller, 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
Miller, 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.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller 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.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. 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 MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.

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.

miller_warr 2016-01

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

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.