Miller PIPEWORX 350 FIELDPRO AND FIELDPRO REMOTE Owners manual

OM-252 932G 2014−04

Processes

Multiprocess Welding

Description

Arc Welding Power Source

PipeWorx 350 FieldPro

t

And FieldPro Remote

Visit our website at

www.MillerWelds.com

File: Multiprocess

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 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 9..............................................

2-5. Principales normes de sécurité 9.........................................................

2-6. Informations relatives aux CEM 9.........................................................

SECTION 3 − DEFINITIONS 11..................................................................

3-1. Additional Safety Symbols And Definitions 11................................................

3-2. Miscellaneous Symbols And Definitions 11..................................................

SECTION 4 − SPECIFICATIONS 12..............................................................

4-1. Serial Number And Rating Label Location 12................................................

4-2. Unit Specifications 12....................................................................

4-3. Duty Cycle And Overheating 12...........................................................

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

4-5. Environmental Specifications 13...........................................................

SECTION 5 − INSTALLATION 14................................................................

5-1. Selecting a Location 14..................................................................

5-2. Proper Method To Carry Remote 15........................................................

5-3. Remote 14 Receptacle Information 15......................................................

5-4. Electrical Service Guide 16...............................................................

5-5. Connecting 1-Phase Input Power 18.......................................................

5-6. Connecting 3-Phase Input Power 20.......................................................

5-7. Weld Output Receptacles And Selecting Cable Sizes* 22......................................

5-8. Stick Connections 23....................................................................

5-9. TIG Lift-Arct Connections 24.............................................................

5-10. Connecting Work Sense Lead To Remote 25................................................

5-11. Optional Method Of Combining Wok Sense Lead With Work Clamp 25...........................

5-12. Connecting Basic Feeder 26..............................................................

5-13. Setting Inductance 26....................................................................

5-14. Installing Welding Power Source Onto Rack 27..............................................

5-15. Connecting To Remote 28................................................................

5-16. Volt Sense Lead And Work Cable Connections For Multiple Welding Arcs 29......................

SECTION 6 − OPERATION 31...................................................................

6-1. Welding Power Source And Remote Interface Controls 31.....................................

6-2. Welding Power Source And Remote Interface Operation Description 32..........................

6-3. Lift-Arc TIG Procedure 33................................................................

6-4. Stick Start Procedure − Scratch Start Technique 33...........................................

6-5. Carbon Arc Gouging 34..................................................................

TABLE OF CONTENTS

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 35.........................................

7-1. Routine Maintenance 35.................................................................

7-2. Blowing Out Inside Of Unit 35.............................................................

7-3. Welding Power Source And Remote Diagnostics Help Codes 36................................

7-4. Feeder Diagnostics Help Codes 38........................................................

7-5. Troubleshooting Welding Power Source 38..................................................

7-6. Troubleshooting Welding Power Source Issues 39............................................

7-7. Power Source Calibration Procedure 39....................................................

SECTION 8 − ELECTRICAL DIAGRAM 42........................................................

SECTION 9 − PARTS LIST 46...................................................................

WARRANTY

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 2013−09

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.

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

power cord ground wire is properly connected to ground terminal in

. 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.

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 equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-252 932 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 may 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-252 932 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 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-252 932 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).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

1-6. EMF Information

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.

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

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 may 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-252 932 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.

fre_som_2013−09

2-1. Symboles utilisés

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.

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

. 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.

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 !

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.

OM-252 932 Page 5

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

s

e

s

-

-

e

e

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.

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher à mains nues les partie

chaudes.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser le

outils recommandés et porter des gants de sou
dage et des vêtements épais pour éviter les brûlu
res.

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 soudag

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
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.

OM-252 932 Page 6

génère des rayons visibles et invisibles intense

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 surchauffement 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 soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs 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 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

t

a
e

r

e

-

SALETES peuvent provoquer des
blessures dans les yeux.

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

pièce à 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.

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 confi-

nés 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

endommagée, elle peut exploser. Du fait que 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 excessi-

ve, 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 sta-

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

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 lors-

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

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

fisamment 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 e

les yeux.

D Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cett
manœuvre est à exécuter dans un endroit sû
lorsque l’on porte l’équipement homologué d
protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute sub

stance inflammable.

OM-252 932 Page 7

LES CHARGES ÉLECTROSTATI-

E

QUES 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 antista-

tiques pour stocker, déplacer 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 BATTERI
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

dépannage, 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.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de

provoquer des interférences.

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

provoquer des interférences avec les équi­pements 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 électri-

cien qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

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.

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.

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

compatible électromagnétiquement.

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

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

D Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

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

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précéden-

tes, 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.

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’entretien en respectant les manuels d’utilisation, les

normes industrielles et les codes nationaux, d’état et locaux.

OM-252 932 Page 8

2-4. Proposition californienne 65 Avertissements

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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 30333 (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 CEM peuvent créer des interférences
avec certains implants médicaux comme des 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
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.

OM-252 932 Page 9

OM-252 932 Page 10

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

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

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

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

Safe1 2012−05

Safe26 2012−05

/

U

U
Hz

A

Amperage

Single / Three

Phase Static

Frequency

Converter-Trans-

former-Rectifier

Off

Protective Earth

(Ground)

Conventional

2

1

Load Voltage

Primary Voltage

Hertz

I

1max

IP

Direct Current

(DC)

Three Phase Single Phase On

Shielded Metal Arc

Welding (SMAW)

SD Logo Is A

Trademark Of The

SD−3C, LLC

Line Connection

Rated Maximum

Supply Current

Internal Protection

Rating

S

U

I

1eff

%

0

Alternating

Current (AC)

Suitable for Some

Hazardous

Locations

Rated No Load

Voltage (Average)

Gas Metal Arc

Welding (GMAW)

Maximum Effective

Supply Current

Percent

V

X

I

2

/

Voltage

Duty Cycle

Rated Welding

Current

Gas Tungsten Arc
Welding (GTAW) /

Tungsten Inert Gas

(TIG) Welding

Single / Three

Phase

OM-252 932 Page 11

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the rear. 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

RMS Amps Input at

Rated Load Output, 60

Hz 3-Phase at NEMA

Load Voltages and

Class I Rating

230 V 460 V 575 V

54.6 25.4 19.9 11.7 11.2

KVA KW

Input

Power

3-Phase

1-Phase

*See Section 4-3 for Duty Cycle Rating.

Rated Output

350 A at 34

VDC, 60%

Duty Cycle*

300 A at 32

VDC, 60%

Duty Cycle*

Voltage

Range in CV Mode

10−44 V 10−350 A 75 VDC 36.1 17.8 14.1 15.0 14.4

4-3. Duty Cycle And Overheating

Amperage

Range in

CC Mode

Max.

Open-

Circuit

Voltage

60% Duty Cycle

6 Minutes Welding 4 Minutes Resting

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

If unit overheats, output stops, a
Help message is displayed and
cooling fan runs. Wait fifteen
minutes for unit to cool. Reduce
amperage or voltage, or duty cycle
before welding.

. Single Phase Operation: The

unit is supplied with a 8 AWG
power cord. The rated output
with 8 AWG is 300 amps, 32
volts at 40% duty cycle. To
achieve 60% duty cycle
change cord to 6 AWG.

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

Overheating

OM-252 932 Page 12

0

Minutes

A or V

15

OR

Reduce Duty Cycle

Ref. 216 568-A

4-4. Dimensions And Weight

Power Source

100 lb (45.4 kg)

22 in.

(559 mm)

17 in.

(432 mm)

12 in.

(305 mm)

Remote

9.08 lb (4.12 kg)

18 in.

(457.2 mm)

4-5. Environmental Specifications

9.75 in.

(247.7 mm)

11.6 in.

(294.6 mm)

4.6 in.

116.8 mm)

18 in.

(457.2 mm)

Ref. 255 179-B / Ref. 255 429-B

IP Rating

IP23

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

OM-252 932 Page 13

SECTION 5 − INSTALLATION

5-1. Selecting a Location

Movement

OR

! Do not move or operate unit

where it could tip.

2

2

1 Lifting Forks
Use lifting forks or hand cart to

move unit.
If using lifting forks, 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.

! Special installation may be

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

Location

1

3

3

18 in.

(460 mm)

18 in.

(460 mm)

OM-252 932 Page 14

loc_2 3/96 - Ref. 151 556 / Ref. 255 179-B

5-2. Proper Method To Carry Remote

1 Handle
Carry Remote only by using the

handle.

1

5-3. Remote 14 Receptacle Information

AJ

K

B

L

C

D

I

NH

M

G

F

E

14 VOLTS DC

REMOTE

OUTPUT

CONTROL

Ref. 255 179-B

255 409-B

Socket* Socket Information

A 14 volts DC. Circuit limited to 35 mA.

B Contact closure to A completes contactor control

circuit.

C Output to remote control; +10 volts DC.

D Remote control circuit common.

E 0 to +10 volts DC input command signal from

remote control.

*The remaining sockets are not used.

NOTICE − HF Arc Starters will damage this unit. Do not use high frequency devices with this unit.

OM-252 932 Page 15

5-4. Electrical Service Guide

Elec Serv 2014−01

NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.

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

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

Installation must meet all National and Local Codes − have only qualified persons make this installation.

Single-Phase 300 A

Input Voltage (V) 230 460 575
Input Amperes (A) At Rated Output 54.6 25.4 19.9
Max Recommended Standard Fuse Rating In Amperes
Time-Delay Fuses
Normal Operating Fuses
Min Input Conductor Size In AWG/Kcmil

2

3

4

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG/Kcmil

4

1

60 30 25
80 40 30

8 12 12

89

(27)

140

(43)

219
(67)

8 12 12

Three-Phase 350 A

Input Voltage (V) 230 460 575
Input Amperes (A) At Rated Output 36.1 17.8 14.1
Max Recommended Standard Fuse Rating In Amperes
Time-Delay Fuses
Normal Operating Fuses
Min Input Conductor Size In AWG/Kcmil

2

3

4

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG/Kcmil

4

1

45 20 15
60 30 20
10 14 14
90

(28)

141
(43)

221
(67)

10 14 14

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-252 932 Page 16

Notes

OM-252 932 Page 17

5-5. Connecting 1-Phase Input Power

1

8

7

L1

L2

3

6

=GND/PE Earth Ground

10

9

1

Tools Needed:

electrical tape

1

2

3

6

5

input1 2012−05 −803 766-C / Ref. 255 179-B

4

OM-252 932 Page 18

5-5. Connecting 1-Phase Input Power (Continued)

! 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.

! Always connect green or green/yellow

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

NOTICE − The Auto-Line circuitry in this unit

automatically adapts the power source to the

primary voltage being applied. Check input

voltage available at site. This unit can be con-

nected to any input power between 208 and
575 VAC without removing cover to relink the
power source.

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

1 Black And White Input Conductor (L1

And L2)
2 Red Input Conductor
3 Green Or Green/Yellow Grounding

Conductor
4 Insulation Sleeving
5 Electrical Tape

Insulate and isolate red conductor as shown.
6 Input Power Cord.

7 Disconnect Device (switch shown in the

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

conductor to disconnect device grounding ter­minal first.

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

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

using Section 5-4 (fused disconnect switch
shown).

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

input1 2012−05

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-252 932 Page 19

5-6. Connecting 3-Phase Input Power

4

3

6

3

= GND/PE Earth Ground

7

2

L1

5

L2

L3

1

Tools Needed:

OM-252 932 Page 20

input2 2012−05 − 803 766-C / Ref. 255 179-B

5-6. Connecting 3-Phase Input Power (Continued)

! 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.

! Always connect green or green/yellow

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

NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input

voltage available at site. This unit can be con­nected to any input power between 208 and
575 VAC without removing cover to relink the
power source.

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

For Three-Phase Operation

1 Input Power Cord.
2 Disconnect Device (switch shown in the

OFF position)

3 Green Or Green/Yellow Grounding

Conductor

4 Disconnect Device Grounding Terminal

5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding

conductor to disconnect device grounding ter­minal first.

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

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

tion using Section 5-4 (fused disconnect
switch shown).

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

input2 2012−05

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-252 932 Page 21

5-7. Weld Output Receptacles And Selecting Cable Sizes*

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

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

Not Exceeding***

Weld Output

Terminals

! Turn off power before

connecting to weld out­put terminals.

! Do not use worn, dam-

aged, undersized, or
repaired cables.

Welding

Amperes

100 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70)

150 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 3/0 (95) 3/0 (95)

100 ft (30 m)

or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 − 100% Duty Cycle

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Electrode

200 2/0 (70) 2/0 (70) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

250 2/0 (70) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120)

300 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120)

350 2/0 (70) 3/0 (95) 4/0 (120)

Work

Output Receptacles

Ref. 255 179-B

* 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)

400 2/0 (70) 3/0 (95) 4/0 (120)

500 3/0 (95) 4/0 (120)

600 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

Ref. S-0007-K 2013−10

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

OM-252 932 Page 22

5-8. Stick Connections

1 Work Output Terminal
Connect work lead to work output

terminal.
2 Electrode Output Terminal
Connect electrode holder to

electrode output terminal.

2

1

255 358-B

Notes

OM-252 932 Page 23

5-9. TIG Lift-Arct Connections

NOTICE − HF Arc Starters will damage this unit.
Do not use high frequency devices with this unit.

NOTICE − HF Arc Starters will
damage this unit. Do not use high

frequency devices with this unit.

1 Work Output Terminal
Connect work lead to work output

terminal.
2 Electrode Output Terminal
Connect TIG torch with gas valve to

electrode output terminal.
3 Gas Cylinder
4 Cylinder Valve
Open valve slightly so gas flow

blows dirt from valve. Close valve.
5 Regulator/Flowmeter
6 Flow Adjust
Typical flow rate is 15 cubic feet per

hour (7.1 liters per minute).

5

6

3

4

Connect torch gas hose to
regulator/flowmeter.

7 Gas Valve
Valve controls gas preflow and

postflow. Open valve on torch just
before welding.

OM-252 932 Page 24

2

7

1

Tools Needed:

11/16 in., 1-1/8 in., (21 mm)

255 357-B

5-10. Connecting Work Sense Lead To Remote

3

4

2

5

1

. The work sense lead is re-

quired for operation of the
FieldPro Remote.

1 Lead
2 Ring Terminal 1/2 in.
If using a ring terminal, slide

terminal onto post on the remote.
3 Wing Nut
Once terminal or wire is on post,

2

5

tighten wing nut.
4 Binding Post
5 Electrical Tape Or Heat Shrink

Tubing

If ring terminal is cut or broken, the
bare wire can be looped around the
post and tightened under the wing
nut.

5-11. Optional Method Of Combining Wok Sense Lead With Work Clamp

1 Work Sense Clamp
2 Ring Terminal 1/2 in.
Disconnect ring terminal from

clamp.

1

3 Work Sense Lead
4 Work Cable
5 Work Clamp

. Be sure that work sense lead

2

3

5

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

Connect work sense lead and work
cable to work clamp.

255 450-A

Tools Needed:

3/8 in.

4

255 449-A

OM-252 932 Page 25

5-12. Connecting Basic Feeder

3

! Turn Off wire feeder and

welding power source. Stop
engine on welding
generator.

1 Welding Power Source
2 Gas Hose
3 Weld Cable To Feeder
4 Work Cable To Workpiece
Weld cable and work cable connec-

tions to power source (DCEN/

1

DCEP) are dependant on wire type.

. Since feeder is not polarity sen-

sitive, there is no need for an
electrode polarity switch.

10

2

5 Workpiece
6 Voltage Sensing Clamp
Connect voltage sensing clamp to

workpiece.
7 Gun
8 Gun Trigger Receptacle
9 FieldProt Feeder (See

OM-258 944 For Feeder

Operation)
10 Gas Cylinder
Use of shielding gas is dependant

on wire type.

. Shielding gas pressure not to

exceed 100 psi (689 kPa).

8

9

6

7

5

4

258 966-A

5-13. Setting Inductance

The power source will display ACC when a FieldPro Feeder is connected to the power source. Press either the Up or Down arrow key to set the
inductance within the range of 0 to 99.

OM-252 932 Page 26

5-14. Installing Welding Power Source Onto Rack

Rack − 195466 Universal Inverter

Mounting Kit − 301100

1

Have only qualified persons make
this installation.

Rack

One Kit Per Machine
(See OM-259 463 For rack
setup and operation)

! Turn Off welding power

sources before inspecting or
installing rack.

1 Rear Rack Mounting Bracket

2

Loosely attach one rack mounting
bracket (with the weld nuts facing
up) on the back of the rack with 2
screws.

2 Welding Power Source
Slide power source onto rack in front

of the bracket.
Align the channels of the rear base

brackets with the rack mounting
bracket. Push the power source
back so the mounting bracket slides
into the channels.

3 Front Rack Mounting Bracket
Slide the second rack mounting

bracket (with the weld nuts facing
up) into the channels on the front
base brackets. Attach bracket to
rack using 2 screws. Tighten all 4
bracket screws to 10 ft lb (13.6 Nm).

1

Rear Of Power Source And Rack

Hole Layout For 4-Pack Rack

Hole Layout For 6-Pack Rack

3

Front Of Power Source And Rack

Tools Needed:

1/2 in.

259 422-A / 254 712-A

OM-252 932 Page 27

5-15. Connecting To Remote

RHC-14 Or Wireless Remote Connection

2

3

6

FieldPro Remote Connection

This power source can be used with
either the FieldPro Remote,
RHC−14 remote or wireless remote
(see RHC−14 remote or wireless
remote Owner’s Manual for
operating instructions).

1 Power Source
2 TIG Torch (Shielding Gas Not

Shown)
3 Electrode Holder
When using a RHC-14 or wireless

remote, connect TIG torch or
electrode holder directly to the

1

4

1

ELECTRODE (top) output
receptacle.

4 Work Cable
Connect work cable to WORK

(bottom) output receptacle on the
front of the welding power source.
Attach work cable clamp as close to
the arc as possible.

5 Work Sense Lead
When using a FieldPro Remote,

attach work sense lead clamp next
to the work cable clamp. Connect
the other end of the work sense
lead to the binding post on the side
of the FieldPro Remote.

6 RHC−14 Remote Or Wireless

Remote
Connect RHC-14 or wireless

remote to 14-pin receptacle on the
front of the power source.

7 FieldPro Remote
Connect one end of the weld cable

to ELECTRODE (top) output
receptacle on the front of the power
source and the other end to the
FieldPro Remote. Connect the TIG
torch or electrode holder to the
other side of the FieldPro Remote.

. The RHC-14 or wireless re-

mote can be used with the

FieldPro Remote to allow am-

perage adjustment during

4

welding.

7

OM-252 932 Page 28

5

2

3

255 420-B

5-16. Volt Sense Lead And Work Cable Connections For Multiple Welding Arcs

A. Ideal Setup

1

2

5

1

6

4

3

5

4

2

3

1 Welding Power Source

2 Weld Cable

3 Work Cable

4 Work Sense Lead

The work sense lead is required for
operation of the FieldPro Remote.

255 378-B

5 Remote
6 Workpiece
This arrangement is an ideal setup for

multiple welding arcs.

OM-252 932 Page 29

B. Bad Setup

1

2

3

1

5

2

4

5

6

4

3

1 Welding Power Source
2 Weld Cable
3 Work Cable

OM-252 932 Page 30

4 Work Sense Lead
5 Remote
6 Workpiece

255 379-B

This arrangement is a bad setup. Clamps
for separate units should not be shared.
Weld cables should not be crossed.

SECTION 6 − OPERATION

6-1. Welding Power Source And Remote Interface Controls

2

4

5

3

8

9

I

ON

1

6 7

101112

OFF

1 Power Switch
2 AMPS Display
3 TIG Process Select Button
4 Stick Process Select Button

5 Stick Electrode Type Select Button
6 Amperage Adjustment Buttons
7 14-Pin Remote Connected Indicator
8 FieldPro Accessory Connected

Indicator

255 429-B / 255 911-A / Ref. 255 179-B / 253 664-A

9 IN USE Button
10 IN USE Indicator
11 Check Polarity Indicator
12 Stick Negative Indicator

OM-252 932 Page 31

6-2. Welding Power Source And Remote Interface Operation Description

Power Switch Use this switch to power up or power down the welding power source.

. The fan is thermostatically controlled and only runs when cooling is needed.

AMPS Display This display illuminates and shows amperage for either TIG or stick welding process. Measured amperage just

TIG Process Select Button Press and release this button to activate the TIG welding process controls. The TIG text below the button

Stick Process Select
Button

Stick Electrode Type
Select Button

prior to the end of a welding operation will appear on the display for ten seconds after welding operation.

illuminates. Adjust the amperage to the appropriate setting within a range from 10 to 350 amps. If the TIG
process has been selected and a remote current/contactor control is connected, holding the TIG process select
button for more than two seconds will display the effective amperage command (based on the amperage setting
and the remote current/contactor control setting).

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. Select the desired stick electrode type and adjust the
amperage to the appropriate setting within a range from 40 to 350 amps.

Press and release button to select the desired stick electrode type (EXX10 or EXX18). The text above or below
the button will illuminate for the active electrode type. This button is only active with the stick welding process
and only then will text for the electrode type illuminate.

. There may be a “clunk” sound from the power source when switching between Stick and TIG

processes. This is part of normal power source operation.

Adjustable DIG and

Hotstart

Amperage Adjustment
Buttons

14-Pin Remote Connected
Indicator

FieldPro ACCESSORY
Connected Indicator

IN USE Button Press and release this button on the power source or FieldPro Remote to illuminate the IN USE text. Press and

IN USE Indicator Light automatically turns on when arc is struck. Toggle light using the IN USE button during use. Light will auto-

CHECK POLARITY
Indicator

STICK NEGATIVE
Indicator

Press and hold the STICK button for a few seconds to enter adjustable DIG. The right decimal point will
illuminate on the display to indicate DIG. Once in adjustable DIG, press and release the STICK button again
to enter adjustable Hotstart. The middle decimal point will illuminate on the display to indicate Hotstart.
Pressing and releasing the STICK button a third time will exit the menu. The menu will automatically exit
after 10 seconds of inactivity. Pressing and releasing any button other than the STICK button while in the
menu will also exit the menu.

Use these buttons to set the desired amperage setting for either TIG or stick welding process.

The 14-PIN REMOTE text will illuminate when there is a 14-pin accessory connected to the Remote 14
receptacle on the power source.

The FieldPro ACCESSORY text will illuminate when there is a FieldPro accessory connected to and properly
communicating with the power source.

release again to turn IN USE text off. This lets others know that the machine is being used.

matically turn off after four hours of inactivity.
The CHECK POLARITY text will illuminate along with an error message (Err) if the work and electrode leads are

reversed. This will light only if a FieldPro accessory is connected. Power down and correct the connections (see
Section 5 for proper connections).

The DCEN (−) STICK NEG text will illuminate if the polarity is negative while in STICK mode. To activate DCEN
mode, press the STICK button and down arrow at the same time. Press the STICK button to exit this mode. The
DCEN mode can be used for EXX10 and/or EXX18 process setting. The mode has to be set for each electrode
process individually.

NOTICE − Controls on the FieldPro Remote are NOT adjustable during welding. To make adjustments during welding, use the power source controls.
Adjustments can be made if using the RHC-14 remote or wireless remote.

Table 6-1. Recommended Process Selections vs Electrode Type

Electrode Type Suggested Process Setting

EXXX1 EXX10
EXXX2 EXX10

EXXX3 EXX18
EXXX4 EXX18
EXXX5 EXX18
EXXX6 EXX18
EXXX7 EXX18
EXXX8 EXX18

Stainless EXX18

OM-252 932 Page 32

6-3. Lift-Arc TIG Procedure

“Touch”

1

1

Second

With Process Switch in the TIG
position, start an arc as follows:

1 TIG Electrode
2 Workpiece
Touch tungsten electrode to work-

piece at weld start point. Arc will not
start while electrode is touching the
workpiece. Slowly lift electrode to
form an arc.

. Do not re-touch the electrode to

2

the workpiece. The arc will go
out and the electrode will stick.

Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with­out overheating, sticking, or getting
contaminated.

. If FieldPro Remote is

connected, its display may
temporarily turn off when the
tungsten touches the work­piece.

Do NOT Strike Like A Match!

6-4. Stick Start Procedure − Scratch Start Technique

1

2

3

Ref. S-156 279

With Stick selected, start arc as
follows:

1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece like

striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.

OM-252 932 Page 33

6-5. Carbon Arc Gouging

1

4

Direction Of

Travel

Recommended rod diameter is 1/4 in. or smaller.

3

2

5

NOTICE − Paralleling machines could
damage units.

1 Electrode Holder
Choose correct electrode holder for the

process.
2 Air Stream
The air stream should be in line with the

electrode and positioned between the
electrode and the workpiece.

3 Carbon Electrode
Choose the correct electrode size for the

OM-252 932 Page 34

desired gouge.
4 Gouging Arc
Keep the arc short.
5 Workpiece
Start air compressor and adjust regulator

to correct setting. Use the lowest air
pressure that will blow away the molten
metal. Ensure that the electrode point is
shaped correctly and insert it in the
electrode holder. The electrode should
extend no more than 7 in. (178 mm) and no
less than 2 in. (51 mm) from the electrode

258 443-A

holder. Strike the arc, then open the air
valve. Use proper arc and travel speed to
create the desired shape and condition of
the gouge.

Always cut away from the operator as
molten metal sprays some distance from
the workpiece.

Ensure that everyone in the work area is
not in the path of the spray.

Remove all combustible material from the
work area. Place metal deflection plates in
front of the operation.

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

Replace

Damaged Or

Unreadable

Labels

! Disconnect power

before maintaining.

3 Months

6 Months

Blow Out Inside

Repair Or

Replace

Cracked

Cables

. Maintain more often

during severe conditions.

Replace Cracked

Torch Body

Repair Or Replace

Cracked Cables

And Cords

Clean

And

Tighten Weld

Connections

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.

Ref. 255 179-B

OM-252 932 Page 35

7-3. Welding Power Source And Remote Diagnostics Help Codes

H1

Display Code Fault Description

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

H02 Secondary Thermistor Malfunction Indicates the left side thermal protection circuitry is

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

H04 Primary Temperature Sensor Malfunction Indicates the right side thermal protection circuitry is

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

H06 Current Foldback Indicates operation at maximum input current. The unit has

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

H12 Precharge Incomplete Indicates the power on precharge cycle did not complete. If this

H13 Internal Voltage Malfunction System cannot measure output voltage. If this code appears on

H16 PC2 Temperature Sensor Malfunction Indicates thermal protection circuitry on the Process Control

H17 PC2 Over Temperature Indicates PC2 has overheated. Unit has shutdown to allow fans

H18 PC3 Temperature Sensor Malfunction Indicates thermal protection circuitry on the System Power

H19 PC3 Over Temperature Indicates PC3 has overheated. Unit has shutdown to allow fans

H20 PC2 Power Supply Low Indicates the control supply on PC2 is malfunctioning. If this

H21 Primary Input Line Voltage Malfunction Indicates input primary line voltage is too low.

H22 Boost Fault Indicates the boost circuitry on the right side of unit is malfunc-

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

0

Display Example

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

malfunctioning. If this 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.

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

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

maximum allowable input current limit. As the line voltage
decreases, the required input current increases. If the line
voltage is too low, the output power is limited by the input
current. When this limit is reached, the unit automatically
reduces output power to continue operation. If this display is
shown, have a qualified electrician check the input voltage.

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

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

the display, contact the nearest Factory Authorized Service
Agent.

board is malfunctioning. If this code appears on the display,
contact the nearest Factory Authorized Service Agent.

to lower temperature. Operation will continue after unit is within
normal temperature range.

board is malfunctioning. If this code appears on the display,
contact the nearest Factory Authorized Service Agent.

to lower temperature. Operation will continue after unit is within
normal temperature range.

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

Primary line voltage must be at least 90% of specified nominal
voltage. If this code appears on the display, have a trained and
qualified service technician check the input voltage.

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

Fault will clear when button is released.

OM-252 932 Page 36

Display Code Fault Description

H27 Polarity Switch Fault Indicates the relay circuitry (W1, W2) is malfunctioning. If this

H30 Stuck Contactor TIG/Stick Indicates a stuck remote contactor in either Stick or TIG pro-

H32 Accessory Temperature Sensor Malfunction Indicates the thermistor in the attached FieldPro accessory is

H33 Accessory Over Temperature Indicates the attached FieldPro accessory has overheated.

H96 PC7 Communication Malfunction Indicates internal communication malfunction to PC7. If this

H97 PC1 Communication Malfunction Indicates internal communication from primary power circuitry

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

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

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

cess. Fault will clear when foot pedal or control device contact­or is released.

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

After arc goes out, the power source will not allow a new arc to
be struck until the accessory has cooled down. Operation will
continue after the accessory is within normal temperature
range.

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

to secondary power circuitry on PC1. If this code appears on
the display, contact the nearest Factory Authorized Service
Agent.

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.

Notes

OM-252 932 Page 37

7-4. Feeder Diagnostics Help Codes

The FieldPro Feeder does not display the same help codes as the power source. Error conditions are indicated by a “HLP” message on the display, or
by the blinking of the Red LED on motor board PC1. To view the Red LED, turn off the power source, remove the wrapper, and turn power source back
on. The Red LED blinks in a 2.5 second cycle. The number of blinks in this period indicates the type of error. If an error condition does not exist on the
motor board, the Red LED is on steady.

H1

Display

Code

H11 1 Blink Communication Error

H12 2 Blinks Trigger Error

H14 4 Blinks (Constant Blinking) Motor Overload

H15 3 Blinks Bus Bar Overheating

Red LED On PC1 Fault Description

0

Display Example

This error occurs 2.5 seconds after a loss
of communication between the motor
board and meter board. The operator may
continue to weld with this error present.
The error may be cleared by turning the
power off, waiting a minimum of 2 seconds,
and turning power back on.

This error occurs if the operator has fed
approximately 35 ft (10.7 m) of wire without
striking an arc, or if the welding wire is
shorted during a welding operation and
switch DIP4 on the front panel board is de­pressed toward the OPEN position. The
error may be cleared by releasing the gun
trigger.

Indicates that the motor has been drawing
too much current for too long. To remedy,
reduce the wire feed speed or the wire
feeder torque load/duty cycle. The error
may be cleared by turning the power off,
waiting a minimum of 2 seconds, and turn­ing the power back on.

Indicates the arc is drawing too much cur­rent for too long. To remedy, reduce the
weld amperage or duty cycle.

7-5. Troubleshooting Welding Power Source

Trouble Remedy

No weld output; unit completely in−operative Place line disconnect switch in On position (see Section 5-6).

Check and replace line fuse(s), if necessary*.

Check for proper input power connections (see Section 5-6).

No weld output; meter display On. Check, repair, or replace RHC-14 remote control.

Unit overheated. Allow unit to cool with fan ON (see Section 4-3).

Check ammeter help displays.

Erratic of improper weld output. Use proper size and type of weld cable.

Clean and tighten all weld connections.

Check volt sense lead. Straighten any coiled cables.

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

*Have a trained and qualified service technician check and replace line fuse(s).

Check RHC-14 remote control switch and potentiometer resistances.

OM-252 932 Page 38

7-6. Troubleshooting Welding Power Source Issues

If the welding power source is 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.

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 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 (TIG welding).

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 does not exceed 90 psi (621 kPa).
S Check all shielding gas fitting and tighten if necessary.
S Shield joint from wind.

FieldPro Remote does not turn on.

S Check work sense lead connection. Be sure that the clamp is connected to a clean, paint-free area of the workpiece.

7-7. Power Source Calibration Procedure

. At any point during voltage or amperage calibration, the IN USE button may be used to advance without saving the calibration. This may be useful

when only wishing to verify calibration and not change the settings. Press the ELECTRODE button at any point to exit calibration mode. Routine
calibration is not necessary for most applications, calibration is verified at the factory.

Required Equipment:

Calibrated voltage meter and ammeter
Load bank or shorting cable

Setup And Enter Calibration Mode:

1. Disconnect output cables including all accessories.

2. Turn power on.

3. To enter calibration mode, press and hold the STICK and IN USE buttons at the same time for 2 seconds. Display will show — — —

4. Release buttons. Display will show CAL. Output will be de-energized. Voltage and current meters should measure zero.

S For Voltage Calibration, connect voltage meter across the output studs. + to ELECTRODE and − to WORK (open circuit load).
S For Amperage Calibration, connect shorting cable or load bank at heavy load setting to output studs. Connect ammeter to measure output current.

. If at any point the display reading is out of the allowed range, unit may need to have the calibration values defaulted. See below for default proced-

ure. If defaulting the calibration does not resolve the issue, the unit may require servicing.

. If at any point the measured voltage or amperage readings are out of the allowed range or are not the correct polarity (+ or −), the unit may require

servicing.

Voltage Calibration Procedure:

1. When in calibration mode, open/disconnect load from output studs, then press the TIG button.

2. Verify the display shows 27.0 (2.0).

3. Verify the voltmeter displays -27.0 (2.0). Verify value is negative.

4. Using the − and + buttons, adjust the display to match the measured value.

5. Wait a few seconds, then verify display and voltmeter reading are the same.

6. Press the TIG button to save the calibration setting.

7. Verify the display shows 72.0 (5.0), indicating open circuit voltage.

8. Verify the voltmeter displays -72.0 (5.0). Verify value is negative.

9. Using the − and + buttons, adjust the display to match the measured value.

10. Wait a few seconds, then verify display and voltmeter reading are the same.

11. Press the TIG button to save the calibration setting.

12. Verify the display shows 27.0 (2.0).

13. Verify the voltmeter displays 27.0 (2.0). Verify value is positive.

14. Using the − and + buttons, adjust the display to match the measured value.

15. Wait a few seconds, then verify display and voltmeter reading are the same.

16. Press the TIG button to save the calibration setting.

17. Verify the display shows 72.0 (5.0), indicating open circuit voltage.

18. Verify the voltmeter displays 72.0 (5.0). Verify value is positive.

OM-252 932 Page 39

19. Using the − and + buttons, adjust the display to match the measured value.

20. Wait a few seconds, then verify display and voltmeter reading are the same.

21. Press the TIG button to save the calibration setting.

22. Press ELECTRODE button to exit calibration mode or continue on to Amperage Calibration procedure.

Amperage Calibration Procedure:

1. When in calibration mode, connecting shorting cable/load bank across output studs, then press the STICK button.

2. Verify the display shows 50 (5.0).

3. Verify the ammeter displays 50 (5.0).

4. Using the − and + buttons, adjust the display to match the measured value.

5. Wait a few seconds, then verify display and ammeter reading are the same.

6. Press the STICK button to save the calibration setting.

7. Verify the display shows 350 (5.0).

8. Verify the ammeter displays 350 (5.0).

9. Using the − and + buttons, adjust the display to match the measured value.

10. Wait a few seconds, then verify display and ammeter reading are the same.

11. Press the STICK button to save the calibration setting.

12. Press ELECTRODE button to exit calibration mode.

Default Calibration Procedure:

S Three levels of calibration default are provided as follows:

Default all Default voltage calibration Default amperage calibration

S Enter calibration mode using the method described above.
S Default all

When in calibration mode, press and hold the STICK and TIG buttons at the same time until the display shows — — —

S Default voltage calibration

When in calibration mode, enter the voltage calibration mode by pressing the TIG button. Then press and hold the STICK and TIG buttons at the
same time until the display shows — — —

S Default amperage calibration

When in calibration mode, enter amperage calibration mode by pressing the STICK button. Then press and hold the STICK and TIG buttons at
the same time until the display shows — — —

Notes

OM-252 932 Page 40

Notes

OM-252 932 Page 41

SECTION 8 − ELECTRICAL DIAGRAM

OM-252 932 Page 42

Figure 8-1. Welding Power Source Circuit Diagram

252 846-E

OM-252 932 Page 43

OM-252 932 Page 44

255 132-B

Figure 8-2. Remote Circuit Diagram

Notes

OM-252 932 Page 45

. Hardware is common and

not available unless listed.

SECTION 9 − PARTS LIST

63

61

47

72

70

79

71

69

71

72

64

78

47

65

59

62

49

56 57

31

56

32

58

75

55

33

19

60

81

67

82

50

48

52

18

65

35

17

34

54

68

53

45

51

80

78

43

26

42

41

28

39

38

37

36

46

16

15

14

13

12

11

7

7

1

8

6

76

44

66

40

73

77

77

OM-252 932 Page 46

30

27

28

26

25

24

23

21

22

29

20

10

7

9

4

Figure 9-1. Welding Power Source Parts Assembly

74

7

5

3

2

255 178-D

Q

uantity

Model

Item

No.

Dia.

Mkgs.

Part

No.

Description

907533 907533001

Figure 9-1. Welding Power Source Parts Assembly

1 257114 Base 1 1... .............. .. ................................................... ....

2 PC5 252120 Nameplate/Switch Membrane, Front Pnl 1 1... ... ...... .. ..................... ....

3 175138 Box, Louver 1 1... .............. .. ............................................. ....

4 170391 Conn, Circ MS Protective Cap 1 1... .............. .. ............................. ....

5 254891 Plate, Switch 1 1... .............. .. ............................................ ....

6 252839 Panel, Front 1 1... .............. .. ............................................. ....

7 268639 Rcpt Assy, Tw Lk Insul Fem(Dinse Type) (Including) 2... .............. .. .................

257995 Rcpt, Tw Lk Insul Fem Dinse Style w/O-ring 1.................... .... .......................

250037 Insulator, Bulkhead Front 1.................... .... .......................................

250039 Insulator, Bulkhead Rear 1.................... .... ........................................

185714 Washer, Tooth 22MMID x 31.5MMOD 1.................... .... ............................

185717 Nut, M20−1.5 1.00 Hex .19H Brs Locking 1.................... .... .........................

185718 O−Ring, 0.989 ID x 0.070 H 1.................... .... .....................................

186228 O−Ring, 0.739 ID x 0.070 H 1.................... .... .....................................

253430 Terminal, Connector Friction 1.................... .... ....................................

7 262559 Rcpt Assy, Tw Lk Insul Fem (Tweco) (Including) 2... .............. .. ..............

267366 Receptacle, Twist Lock Tweco .890 OD w/O-ring 1.................... .... ...........

250037 Insulator, Bulkhead Front .890 OD 1.................... .... ........................

250039 Insulator, Bulkhead Rear .890 OD 1.................... .... .........................

185714 Washer, Tooth 22MMID x 31.5MMOD 1.................... .... .....................

185717 Nut, M20−1.5 1.00 Hex .19H Brs Locking 1.................... .... ..................

185718 O−Ring, 0.989 ID x 0.070 H 1.................... .... ..............................

186228 O−Ring, 0.739 ID x 0.070 H 1.................... .... ..............................

253430 Terminal, Connector Friction 1.................... .... .............................

8 C6 264077 Capacitor Assy 1 1... .... ...... .. ........................................... ....

9 254892 Door, SD Reader 1 1... .............. .. ......................................... ....

10 234344 Bracket, SD Card Reader 1 1... .............. .. ................................. ....

11 PC4 244477 Circuit Card Assy, SD Card 1 1... ... ...... .. ................................ ....

12 PC6 253408 Circuit Card Assy, Source Remote Interface 1 1... ... ...... .. ................. ....

13 FM1 224694 Fan 1 1... ... ...... .. ..................................................... ....

14 176226 Insulator, Switch Power 1 1... .............. .. ................................... ....

15 S1 244920 Switch 1 1... .... ...... .. .................................................. ....

253664 Label, On−Off 1 1.................... .. ............................................ ....

16 225097 Heat Sink, Rect LH 1 1... .............. .. ....................................... ....

17 211503 Insulator, Heat Sink 1 1... .............. .. ....................................... ....

18 T1 212132 Xfmr, HF Litz/Litz w/Boost 1 1... .... ...... .. ................................. ....

19 L3 212150 Inductor, Output 1 1... .... ...... .. .......................................... ....

20 212207 Windtunnel, LH 1 1... .............. .. .......................................... ....

21 196355 Insulator, Screw 4 4... .............. .. .......................................... ....

22 D1,D2 201531 Kit, Diode Power Module 2 2... .. ..... .. .................................. ....

23 199840 Bus Bar, Diode 2 2... .............. .. ........................................... ....

24 R3/C4 233052 Resistor/Capacitor 1 1... .. ..... .. ........................................ ....

25 SR1 201530 Kit, Diode Fast Recovery Bridge 1 1... ... ...... .. ............................ ....

26 RT1,RT2 199798 Thermistor, NTC 30k ohm @ 25 Deg C 18.00 in. 2500V 2 2... . .... .. ....... ....

27 HD1 182918 Transducer, Current 400A Module Supply V +/− 15V 1 1... ... ...... .. .......... ....

28 179276 Bushing, Snap−In Nyl 1.000 ID X 1.375 Mtg Hole Cent 3 3... .............. .. ........ ....

29 170647 Bushing, Snap−In Nyl 1.312 ID X 1.500 Mtg Hole 1 1... .............. .. ............. ....

30 CR1 198549 Relay, Encl 24VDC SPST 35A/300VAC 4pin Flange Mtg 1 1... ... ...... .. ..... ....

31 PC7 255714 Circuit Card Assy, WCC Interface 1 1... ... ...... .. ........................... ....

32 252923 Bracket, Mtg WCC Board 1 1... .............. .. .................................. ....

33 010546 Bushing, Snap−In Nyl .375 ID X .500 Mtg Hole 1 1... .............. .. .............. ....

34 L4 218020 Inductor, Boost 1 1... .... ...... .. ........................................... ....

35 227746 Gasket, Inductor Mounting E55 Ferrite Core 1 1... .............. .. ................. ....

36 196330 Heat Sink, Power Module 1 1... .............. .. .................................. ....

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-252 932 Page 47

Q

uantity

Model

Item

No.

Dia.

Mkgs.

Part

No.

Description

907533 907533001

Figure 9-1. Welding Power Source Parts Assembly
(Continued)

37 L2 218018 Inductor, Pre−Regulator 1 1... .... ...... .. ................................... ....

38 218566 Gasket, Inductor Mounting E70 Ferrite Core 1 1... .............. .. ................. ....

39 212206 Windtunnel, RH 1 1... .............. .. .......................................... ....

40 MOD1,... .. ...........

MOD2 217625 Kit, Input/Pre−regulator And Invertor Module 1 1..... .. ................. ....

41 153403 Bushing, Snap−In Nyl .750 ID X 1.000 Mtg Hole Cent 2 2... .............. .. ......... ....

42 219472 Bracket, Mtg Capacitor Series 1 1... .............. .. ............................. ....

43 C15 196143 Capacitor, Polyp Met Film 16. uf 400 VDC 10% 1 1... ... ...... .. .............. ....

44 PC2 258042 Circuit Card Assy, Interconnect W/Label And Clips 1 1... ... ...... .. ............ ....

45 L1 212091 Inductor, Input 1 1... .... ...... .. ........................................... ....

46 RM1,... ..

PLG26 205751 Module, Power Resistor W/Plug 1 1.... .. ............................ ....

47 +252842 Panel, Side 2 2... ............. .. .............................................. ....

47 +268254 Panel, Side Red−D−Arc 2 2... ............. .. ................................... ....

48 257258 Bracket Upper, Mtg Capacitor/PC Board 1 1... .............. .. ..................... ....

49 PC1 256983 Circuit Card Assy, FC Power Source Ctrl Potted 1 1... ... ...... .. .............. ....

50 257260 Bracket, Capacitor Support 1 1... .............. .. ................................ ....

51 C12,C13 193738 Capacitor, Elctlt 1800 uf 500 VDC Can 2.52 Dia 2 2... . .... .. .............. ....

52 217040 Nut, Nylon M12 Thread Capacitor Mounting 2 2... .............. .. .................. ....

53 FM2 183918 Fan 1 1... ... ...... .. ..................................................... ....

54 252855 Bracket, Mtg Contactors 1 1... .............. .. ................................... ....

55 W1,W2 247571 Contactor, Latching 2 2... .. .... .. ....................................... ....

56 254967 Bus Bar, Input 2 2... .............. .. ........................................... ....

57 254968 Bus Bar, Output 2 2... .............. .. .......................................... ....

58 PC3 252949 Circuit Card Assy, Autoline Cntrl Power 70W Potted 1 1... ... ...... .. ........... ....

59 257115 Panel,Rear 1 1... .............. .. .............................................. ....

60 182455 Nut, Conduit 1.000 Npt Knurled 1 1... .............. .. ............................ ....

61 215980 Bushing, Strain Relief .709/.984 ID x 1.375 Mtg Hole 1 1... .............. .. .......... ....

62 252930 Insulator, Rear Panel 1 1... .............. .. ..................................... ....

63 257239 Cable, Power 12 ft 8 ga 4c (Non−Stripped End) 1 1... .............. .. ............. ....

64 +252841 Cover, Top 1 1... ............. .. .............................................. ....

64 +268255 Cover, Top Red−D−Arc 1 1... ............. .. .................................... ....

65 256025 Insulator, Side 2 2... .............. .. ........................................... ....

66 CT1 253320 Xfmr, Current Sensing 200/1 W/15 in. Leads 1 1... ... ...... .. ................. ....

67 257124 Bracket, Mtg Terminal Block 1 1... .............. .. ............................... ....

68 198951 Block, Terminal 3 Pole 1 1... .............. .. .................................... ....

69 257044 Bracket, Top Extruded 4 4... .............. .. .................................... ....

70 257047 Handle, Carrying Pwxfld 2 2... .............. .. ................................... ....

71 257049 Handle, Formed Top 2 2... .............. .. ...................................... ....

72 257045 Bracket, Side Support 4 4... .............. .. ..................................... ....

73 257043 Bracket, Base Extruded 4 4... .............. .. ................................... ....

74 252115 Circuit Card Assy, Front Panel Pwxfld Ps/Rmt W/Pgm 1 1... .............. .. ......... ....

75 257259 Bracket Lower, Mtg Capacitor/PC Board 1 1... .............. .. ..................... ....

76 257382 Bracket, Capacitor Guard 1 1... .............. .. .................................. ....

77 257048 Handle, Formed Bottom 2 2... .............. .. ................................... ....

78 147139 Tape, Adh Acrylic Double Sided .010 x .500 x 3.000 16 16... .............. .. ........... ....

79 257050 Bearing, Handle Pwxfld Ps 4 4... .............. .. ................................ ....

80 233397 Insulator, Board Bracket Capacitor 1 1... .............. .. .......................... ....

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS

OM-252 932 Page 48

Q

uantity

Model

Item

No.

Dia.

Mkgs.

Part

No.

Description

907533 907533001

Figure 9-1. Welding Power Source Parts Assembly
(Continued)

81 191944 Capacitor,Polyp Met Film 10. Uf 250 Vac 10% 1 1... .............. .. ................ ....

82 194254 Core,Toroidal 22.25mm Id X 36.96mm Od X 15.88mm Th 1 1... .............. .. ..... ....

255736 Core, Ferrite Emi Snap-on .393 ID x .877 OD x 1.250 thk 3 3.................... .. ...... ....

PLG51,PLG118,....

PLG72,

PLG117 255063 Housing Plug+Skts, (Service Kit) 4 4.... .. ........................... ....

PLG73 256953 Housing Plug+Skts, (Service Kit) 1 1........ .... .. ........................... ....

PLG21 115091 Housing Plug+Skts, (Service Kit) 1 1........ .... .. ........................... ....

PLG14,PLG34,....

PLG23 115092 Housing Plug+Skts, (Service Kit) 3 3.... .. ........................... ....

PLG32,.......

PLG115 115094 Housing Plug+Skts, (Service Kit) 2 2.... .. ........................... ....

PLG33,.......

PLG14 130203 Housing Plug+Skts, (Service Kit) 3 3.... .. ........................... ....

PLG13,PLG35,....

PLG2/RC2 131054 Housing Plug+Skts, (Service Kit) 3 3... .. ........................... ....

PLG12 131056 Housing Plug+Skts, (Service Kit) 1 1........ .... .. ........................... ....

PLG11 131204 Housing Plug+Skts, (Service Kit) 1 1........ ..... .. ........................... ....

RC3/PLG3 135635 Housing Plug+Skts, (Service Kit) 1 1...... ... .. ........................... ....

PLG111,PLG22,....

PLG31,

PLG113 201665 Housing Plug+Skts, (Service Kit) 4 4.... .. ........................... ....

227127 Label, Warning Electric Shock/Exploding Parts 1 1.................... .. ............... ....

153178 Label, Warning Exploding Parts Can Serious Injury 2 2.................... .. ........... ....

134327 Label, Warning General Precautionary Static&Wire Fe 2 2.................... .. ........ ....

138442 Label, Warning Falling Equipment Can Cause Injury 2 2.................... .. .......... ....

217480 Label, Warning Incorrect Connections 1 1.................... .. ....................... ....

126026 Label, Warning Electric Shock Can Kill Significant 1 1.................... .. ............ ....

121389 Label, Miller 12.437 x 5.250 Horizontal 2 2.................... .. ...................... ....

255399 Label, Notice HF Will Damage 1 1.................... .. ............................. ....

047409 LABEL, WORK 1 1.................... .. .......................................... ....

047410 Label, Electrode 1 1.................... .. .......................................... ....

155436 Label, Ground/Protective Earth 1 1.................... .. ............................. ....

252846 Ckt, Pipeworx 350 Fieldpro 1 1.................... .. ................................ ....

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-252 932 Page 49

. Hardware is common and

not available unless listed.

8

10

3

15

16

9

1

14

15

12

5

13

16

6

11

2

7

17

19

18

4

Figure 9-2. Remote Parts Assembly

255 407-B

OM-252 932 Page 50

Q

uantity

Model

Item

No.

Dia.

Mkgs.

Part

No.

Description

300934 300934001

Figure 9-2. Remote Parts Assembly

1 +253680 Case, Molded (Including) 1 1... ............. .. .................................. ....

2 253723 Base, Remote 1 1... .............. .... .......................................... ....

3 253372 Pouch, Nylon 1000 Denier W/Velcro 1 1... .............. .... ....................... ....

4 253671 Gasket, Remote 1 1... .............. .. .......................................... ....

5 253666 Bus Bar, LEM 1 1... .............. .. ............................................ ....

6 HD1 191941 Transducer, Current 200A Module Supply V+/− 15V 1 1... ... ...... .. ........... ....

7 255046 Insert, Nyl 2 2... .............. .. ............................................... ....

8 255045 Cable, Volt Sense 15 ft w/Clamp & Term 1 1... .............. .. ..................... ....

9 242239 Conn, Tw Lk Insul Male(Dinse Type)1/0-2/0 Blk 1... .............. .. .....................

8 191981 Conn, Tw Lk Insul Male (Tweco/Lenco Type) 1/0−2/0 Blk 1... .............. .. ......

10 242240 Conn, Tw Lk Insul Fem (Dinse Type) 1/0-2/0 Blk 1... .............. .. .....................

9 218677 Conn, Tw Lk Insul Fem (Tweco/Lenco Thpe) 1/0−2/0 Blk 1... .............. .. ......

11 PC1 255721 Circuit Card Assy 1 1... ... ...... .. ......................................... ....

12 026947 Stand−Off, Insul .250−20 x 1.000 Lg x .312 Thd 2 2... .............. .. .............. ....

13 254969 Stand−Off, No 6−32 x 1.375 Lg .250 Hex Al Fem 2 2... .............. .. ............. ....

14 254883 Stud, Brass 1 1... .............. .. .............................................. ....

255326 Label, PipeWorx 350 Field Remote 1 1.................... .. ......................... ....

214521 Label, Warning Turn Off Power Before Opening 1 1.................... .. .............. ....

255253 Label, Warning Disconnect Input Power Before Servicing 1 1.................... .. ...... ....

PLG12,.......

PLG21,

PLG14 255063 Housing Plug + Skts, (Service Kit) 3 3.... .. .......................... ....

15 121276 Bushing, Strain Relief .450/.709 ID x 1.115 Mtg Hol 2 2... .............. .. ........... ....

16 254257 Lead List, Large 2 2... .............. .. .......................................... ....

17 258463 Spacer, Nylon 010-32 x 2.500 x .500 Hex 4 4... .............. .. .................... ....

18 256973 Nameplate/Switch Membrane, Front Pnl Pwxfld Rmt 1 1... .............. .. .......... ....

19 252115 Circuit Card Assy, Front Panel Pwxfld Ps/Rmt W/Pgm 1 1... .............. .. ......... ....

255133 Plugs, w/Leads (User Interface) 1 1.................... .. ............................ ....

255145 Cable, LEM Pipeworx 350 Field Remote 1 1.................... .. ..................... ....

255326 Label, Nameplate Pipeworx 350 Field Remote 1 1.................... .. ................ ....

255259 Label, Notice Only Fieldpro Compatible 1 1.................... .. ..................... ....

258410 Card, Quick Reference Guide 1 1.................... .. .............................. ....

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-252 932 Page 51

Notes

Notes

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in.) (0.64 mm)
22 Gauge (.031 in.) (0.79 mm)
20 Gauge (.037 in.) (0.94 mm)

18 Gauge (.050 in.) (1.27 mm)
16 Gauge (.063 in.) (1.60 mm)
14 Gauge (.078 in.) (1.98 mm)

1/8 in. (.125 in.) (3.18 mm)

3/16 in. (.188 in.) (4.78 mm)

1/4 in. (.25 in.) (6.35 mm)

5/16 in. (.313 in.) (7.95 mm)

3/8 in. (.375 in.) (9.53 mm)

1/2 in. (.5 in.) (12.70 mm)

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, 2014

(Equipment with a serial number preface of ME 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.

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 Welding Generators

(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* 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)
* 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.)

* 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) Guns
* 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 2014−01−14

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  2014 Miller Electric Mfg. Co. 2014−01

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.