OM-273473D 2016−11

Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging

Description

Arc Welding Power Source

Auto−Continuum
350 And 500
w/ Insight Coret

For product information,

Owner’s Manual translations, File: Advanced Manufacturing Systems
and more, visit
[Link]
 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 Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
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 parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.

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
[Link] on the web.

Mil_Thank 2009−09
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. 350 Model Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. 500 Model Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-3. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4. Remote 10 Wire Feeder Control Receptacle RC2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-5. Volt Sense Receptacle RC3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-6. Peripheral Receptacle RC22 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-7. Supplementary Protector CB1, Communication Panel, And E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-8. Aux Power And CB2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-9. Devicenet Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-11. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 6 − RECOMMENDED SETUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Welding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-3. Using Multiple Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs . . . . . . . . . . . . . . . . . 27
6-5. Earth Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-6. 30 Points Of Mechanics In MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-7. Arc Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-8. Basic Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
 TABLE OF CONTENTS

SECTION 7 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-1. Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-2. User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-3. Description Of Front Panel Controls (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 8 − CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-1. Accessing Configuration Web Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-2. Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-3. Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-4. Arc Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-5. Data Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8-6. Help Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-3. Error Code Troubleshooting Description And Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 11 − PARTS LIST FOR 350 AND 500 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7

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

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

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
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Arc Welding Hazards

D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is D Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
D If AC output is required, use remote output control if present on
unit. D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
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
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder HOT PARTS can burn.
is recommended. And, do not work alone!
D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to D Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
D Properly install, ground, and operate this equipment according to D To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.

OM-273473 Page 1
 D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.

Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.

drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot Compressed gas cylinders contain gas under high
workpiece, and hot equipment can cause fires and pressure. If damaged, a cylinder can explode. Since
burns. Accidental contact of electrode to metal objects can cause gas cylinders are normally part of the welding
sparks, explosion, overheating, or fire. Check and be sure the area is process, be sure to treat them carefully.
safe before doing any welding.
D Protect compressed gas cylinders from excessive heat, mechani-
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If cal shocks, physical damage, slag, open flames, sparks, and arcs.
this is not possible, tightly cover them with approved covers. D Install cylinders in an upright position by securing to a stationary
D Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
D Protect yourself and others from flying sparks and hot metal. D Keep cylinders away from any welding or other electrical circuits.
D Be alert that welding sparks and hot materials from welding can D Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas.
D Never allow a welding electrode to touch any cylinder.
D Watch for fire, and keep a fire extinguisher nearby.
D Never weld on a pressurized cylinder − explosion will result.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. D Use only correct compressed gas cylinders, regulators, hoses,
D Do not weld on containers that have held combustibles, or on and fittings designed for the specific application; maintain them
closed containers such as tanks, drums, or pipes unless they are and associated parts in good condition.
properly prepared according to AWS F4.1 and AWS A6.0 (see D Turn face away from valve outlet when opening cylinder valve. Do
Safety Standards). not stand in front of or behind the regulator when opening the valve.
D Do not weld where the atmosphere can contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-273473 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

D Do not install or place unit on, over, or near D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit. guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
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
READ INSTRUCTIONS.
extend beyond opposite side of unit.
D Read and follow all labels and the Owner’s
D Keep equipment (cables and cords) away from moving vehicles Manual carefully before installing, operating, or
when working from an aerial location. servicing unit. Read the safety information at
D Follow the guidelines in the Applications Manual for the Revised the beginning of the manual and in each
NIOSH Lifting Equation (Publication No. 94−110) when manu- section.
ally lifting heavy parts or equipment. D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
OVERUSE can cause OVERHEATING local codes.
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. H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
FLYING SPARKS can injure. navigation, safety services, computers, and
communications equipment.
D Wear a face shield to protect eyes and face.
D Have only qualified persons familiar with
D Shape tungsten electrode only on grinder with electronic equipment perform this installation.
proper guards in a safe location wearing proper
face, hand, and body protection. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
D Sparks can cause fires — keep flammables away. tion.
D If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts. ARC WELDING can cause interference.
D Keep away from pinch points such as drive D Electromagnetic energy can interfere with
rolls. sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
WELDING WIRE can injure. D Be sure all equipment in the welding area is
electromagnetically compatible.
D Do not press gun trigger until instructed to do
so. D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Do not point gun toward any part of the body,
other people, or any metal when threading D Locate welding operation 100 meters from any sensitive elec-
welding wire. tronic equipment.
D Be sure this welding machine is installed and grounded
BATTERY EXPLOSION can injure. according to this manual.
D If interference still occurs, the user must take extra measures
D Do not use welder to charge batteries or jump such as moving the welding machine, using shielded cables,
start vehicles unless it has a battery charging using line filters, or shielding the work area.
feature designed for this purpose.

OM-273473 Page 3
1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, CSA Standard
is available as a free download from the American Welding Society at W117.2, from Canadian Standards Association, Standards Sales, 5060
[Link] or purchased from Global Engineering Documents Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 1-877-413-5184, website: [Link]). (phone: 800-463-6727, website: [Link]).
Safe Practice For Occupational And Educational Eye And Face Protec-
Safe Practices for the Preparation of Containers and Piping for Welding tion, ANSI Standard Z87.1, from American National Standards Institute,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
al Engineering Documents (phone: 1-877-413-5184, website: site: [Link]).
[Link]). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: [Link]).
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: [Link]). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
National Electrical Code, NFPA Standard 70, from National Fire Protec- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
[Link] and www. [Link]). phone for Region 5, Chicago, is 312-353-2220, website:
[Link]).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Applications Manual for the Revised NIOSH Lifting Equation, The Na-
from Compressed Gas Association, 14501 George Carter Way, Suite tional Institute for Occupational Safety and Health (NIOSH), 1600
103, Chantilly, VA 20151 (phone: 703-788-2700, website:[Link]- Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
[Link]). [Link]/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields can interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
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: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

OM-273473 Page 4
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7

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

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
AVIS − Indique des déclarations pas en relation avec des blessures afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

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

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
Les symboles représentés ci-dessous sont utilisés dans ce ma- stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
nuel pour attirer l’attention et identifier les dangers possibles. En l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
présence de l’un de ces symboles, prendre garde et suivre les mes de sécurité).
instructions afférentes pour éviter tout risque. Les instructions
D Installez, mettez à la terre et utilisez correctement cet équipement
en matière de sécurité indiquées ci-dessous ne constituent
conformément à son Manuel d’Utilisation et aux réglementations
qu’un sommaire des instructions de sécurité plus complètes
nationales, gouvernementales et locales.
fournies dans les normes de sécurité énumérées dans la Sec-
tion 2-5. Lire et observer toutes les normes de sécurité. 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
Seul un personnel qualifié est autorisé à installer, faire fonc-
cordon est raccordée à une prise correctement mise à la terre.
tionner, entretenir et réparer cet appareil.
D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil. D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
UNE DÉCHARGE ÉLECTRIQUE peut D Vérifier fréquemment le cordon d’alimentation et le conducteur de
entraîner la mort. mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
Le contact d’organes électriques sous tension peut le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî-
provoquer des accidents mortels ou des brûlures ner la mort.
graves. Le circuit de l’électrode et de la pièce est sous D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
machine sont également sous tension lorsque l’alimen- sante ou mal épissés.
tation est sur Marche. Dans le mode de soudage avec D Ne pas enrouler les câbles autour du corps.
du fil, le fil, le dérouleur, le bloc de commande du D Si la pièce soudée doit être mise à la terre, le faire directement
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement avec un câble distinct.
installé ou mis à la terre de manière incorrecte ou D Ne pas toucher l’électrode quand on est en contact avec la pièce,
impropre constitue un danger. la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
D Ne pas toucher aux pièces électriques sous tension. en même temps à cause de la présence d’une tension à vide dou-
D Porter des gants isolants et des vêtements de protection secs et blée.
sans trous. D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
D S’isoler de la pièce à couper et du sol en utilisant des housses ou champ les pièces endommagées. Entretenir l’appareil conformé-
des tapis assez grands afin d’éviter tout contact physique avec la ment à ce manuel.
pièce à couper ou le sol. D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D Ne pas se servir de source électrique à courant électrique dans les D S’assurer que tous les panneaux et couvercles sont correctement
zones humides, dans les endroits confinés ou là où on risque de en place.
tomber.
D Fixer le câble de retour de façon à obtenir un bon contact métal-
D Se servir d’une source électrique à courant électrique UNIQUE- métal avec la pièce à souder ou la table de travail, le plus près pos-
MENT si le procédé de soudage le demande. sible de la soudure.
D Si l’utilisation d’une source électrique à courant électrique s’avère D Isoler la pince de masse quand pas mis à la pièce pour éviter le
nécessaire, se servir de la fonction de télécommande si l’appareil contact avec tout objet métallique.
en est équipé. D Ne pas raccorder plus d’une électrode ou plus d’un câble de
D D’autres consignes de sécurité sont nécessaires dans les condi- masse à une même borne de sortie de soudage. Débrancher le
tions suivantes : risques électriques dans un environnement câble pour le procédé non utilisé.
humide ou si l’on porte des vêtements mouillés ; sur des structures D Utiliser une protection différentielle lors de l’utilisation d’un équi-
métalliques telles que sols, grilles ou échafaudages ; en position
pement auxiliaire dans des endroits humides ou mouillés.
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 Il reste une TENSION DC NON NÉGLIGEABLE dans
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
les sources de soudage onduleur UNE FOIS
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à l’alimentation coupée.
souder AC à tension à vide réduite. Dans la plupart des situations, D Arrêter les convertisseurs, débrancher le courant électrique et
l’utilisation d’un poste à souder DC à fil à tension constante est re- décharger les condensateurs d’alimentation selon les instructions
commandée. En outre, ne pas travailler seul ! indiquées dans la partie Entretien avant de toucher les pièces.
OM-273473 Page 5
 chauffement ou un incendie. Avant de commencer le soudage, vérifier
LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger.
provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de
D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
D Prévoir une période de refroidissement avant soigneusement avec des protections homologués.
de travailler à l’équipement. D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- D Se protéger et d’autres personnes de la projection d’étincelles et
dés et porter des gants de soudage et des vêtements épais pour de métal chaud.
éviter les brûlures. D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
LES FUMÉES ET LES GAZ peuvent fissures et des ouvertures.
être dangereux. D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage génère des fumées et des gaz. Leur
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
inhalation peut être dangereux pour votre santé. peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
D Eloigner votre tête des fumées. Ne pas respirer les fumées. des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au préparés correctement conformément à AWS F4.1 et AWS A6.0
niveau de l’arc pour l’évacuation des fumées et des gaz de (voir les Normes de Sécurité).
soudage. Pour déterminer la bonne ventilation, il est recommandé D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
de procéder à un prélèvement pour la composition et la quantité gaz ou émanations inflammables (vapeur d’essence, par exemple).
de fumées et de gaz auxquels est exposé le personnel. D Brancher le câble de masse sur la pièce le plus près possible de la
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs zone de soudage pour éviter le transport du courant sur une
approuvé. longue distance par des chemins inconnus éventuels en provo-
D Lire et comprendre les fiches de données de sécurité et les instruc- quant des risques d’électrocution, d’étincelles et d’incendie.
tions du fabricant concernant les adhésifs, les revêtements, les D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
nettoyants, les consommables, les produits de refroidissement, les lées.
dégraisseurs, les flux et les métaux. D En cas de non utilisation, enlever la baguette d’électrode du porte-
D Travailler dans un espace fermé seulement s’il est bien ventilé ou électrode ou couper le fil à la pointe de contact.
en portant un respirateur à alimentation d’air. Demander toujours à D Porter un équipement de protection pour le corps fait d’un matériau
un surveillant dûment formé de se tenir à proximité. Des fumées et résistant et ignifuge (cuir, coton robuste, laine). La protection du
des gaz de soudage peuvent déplacer l’air et abaisser le niveau corps comporte des vêtements sans huile comme par ex. des
d’oxygène provoquant des blessures ou des accidents mortels. gants de cuir, une chemise solide, des pantalons sans revers, des
S’assurer que l’air de respiration ne présente aucun danger. chaussures hautes et une casquette.
D Ne pas souder dans des endroits situés à proximité d’opérations D Avant de souder, retirer toute substance combustible de vos po-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et ches telles qu’un allumeur au butane ou des allumettes.
les rayons de l’arc peuvent réagir en présence de vapeurs et for- D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
mer des gaz hautement toxiques et irritants. trace d’étincelles incandescentes ni de flammes.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- Ne pas augmenter leur puissance; ne pas les ponter.
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
bien ventilé, et en portant un respirateur à alimentation d’air. Les NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
revêtements et tous les métaux renfermant ces éléments peuvent extincteur à proximité.
dégager des fumées toxiques en cas de soudage. D Lire et comprendre les fiches de données de sécurité et les instruc-
tions du fabricant concernant les adhésifs, les revêtements, les
LES RAYONS DE L’ARC peuvent nettoyants, les consommables, les produits de refroidissement,
provoquer des brûlures dans les les dégraisseurs, les flux et les métaux.
yeux et sur la peau. DES PIECES DE METAL ou DES
Le rayonnement de l’arc du procédé de soudage génère SALETES peuvent provoquer des
des rayons visibles et invisibles intenses (ultraviolets e blessures dans les yeux.
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage. D Le soudage, l’écaillement, le passage de la pièce à
D Porter un casque de soudage approuvé muni de verres filtrants la brosse en fil de fer, et le meulage génèrent des étincelles et des
approprié pour protéger visage et yeux pour protéger votre visage particules métalliques volantes. Pendant la période de ref-
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 roidissement des soudures, elles risquent de projeter du laitier.
et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux ou un écran
D Porter des lunettes de sécurité avec écrans latéraux même sous facial.
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour LES ACCUMULATIONS DE GAZ
protéger les autres contre les rayonnements les éblouissements risquent de provoquer des blessures
et les étincelles ; prévenir toute personne sur les lieux de ne pas ou même la mort.
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau D Fermer l’alimentation du gaz comprimé en cas
résistant et ignifuge (cuir, coton robuste, laine). La protection du de non utilisation.
corps comporte des vêtements sans huile comme par ex. des D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
gants de cuir, une chemise solide, des pantalons sans revers, des respirateur d’adduction d’air homologué.
chaussures hautes et une casquette.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
LE SOUDAGE peut provoquer un peuvent affecter les implants médicaux.
incendie ou une explosion.
D Les porteurs de stimulateurs cardiaques et
Le soudage effectué sur des conteneurs fermés tels autres implants médicaux doivent rester à
que des réservoirs, tambours ou des conduites peut distance.
provoquer leur éclatement. Des étincelles peuvent
D Les porteurs d’implants médicaux doivent consulter leur médecin
être projetées de l’arc de soudure. La projection d’étincelles, des
et le fabricant du dispositif avant de s’approcher de la zone où se
pièces chaudes et des équipements chauds peut provoquer des incen- déroule du soudage à l’arc, du soudage par points, du gougeage,
dies et des brûlures. Le contact accidentel de l’électrode avec des de la découpe plasma ou une opération de chauffage par
objets métalliques peut provoquer des étincelles, une explosion, un sur- induction.
OM-273473 Page 6
 D Tenir les bouteilles éloignées des circuits de soudage ou autres
LE BRUIT peut endommager l’ouïe. circuits électriques.
Le bruit des processus et des équipements peut D Ne jamais placer une torche de soudage sur une bouteille à gaz.
affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec
D Porter des protections approuvées pour les une bouteille.
oreilles si le niveau sonore est trop élevé. D Ne jamais souder une bouteille pressurisée − risque d’explosion.
LES BOUTEILLES peuvent exploser D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
si elles sont endommagées.
les maintenir ainsi que les éléments associés en bon état.
Les bouteilles de gaz comprimé contiennent du D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
gaz sous haute pression. Si une bouteille est de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
endommagée, elle peut exploser. Du fait que de l’ouverture de la vanne.
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution. D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des D Utiliser les équipements corrects, les bonnes procédures et suffi-
flammes ouvertes, des étincelles et des arcs. samment de personnes pour soulever et déplacer les bouteilles.
D Placer les bouteilles debout en les fixant dans un support station- D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
naire ou dans un porte-bouteilles pour les empêcher de tomber ou l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
de se renverser. Association) mentionné dans les principales normes de sécurité.

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

D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-
Risque D’INCENDIE OU D’EXPLOSION. placer ou expédier des cartes de circuits imprimes.
D Ne pas placer l’appareil sur, au-dessus ou Les PIÈCES MOBILES peuvent
à proximité de surfaces inflammables. causer des blessures.
D Ne pas installer l’appareil à proximité de pro-
duits inflammables. D Ne pas s’approcher des organes mobiles.
D Ne pas surcharger l’installation électrique − s’assurer que D Ne pas s’approcher des points de coincement
l’alimentation est correctement dimensionnée et protégée avant tels que des rouleaux de commande.
de mettre l’appareil en service.
LES FILS DE SOUDAGE peuvent
LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.
provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en
D Utiliser l’anneau de levage uniquement pour avoir reçu l’instruction.
soulever l’appareil, NON PAS les chariots, les D Ne pas diriger le pistolet vers soi, d’autres
bouteilles de gaz ou tout autre accessoire. personnes ou toute pièce mécanique en engageant le fil de
D Utiliser un équipement de levage de capacité suffisante pour lever soudage.
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer L’EXPLOSION DE LA BATTERIE
que les fourches sont suffisamment longues pour dépasser du peut provoquer des blessures.
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules D Ne pas utiliser l’appareil de soudage pour
mobiles lors de toute opération en hauteur. charger des batteries ou faire démarrer des
D Suivre les consignes du Manuel des applications pour l’équation véhicules à l’aide de câbles de démarrage,
de levage NIOSH révisée (Publication Nº94–110) lors du levage sauf si l’appareil dispose d’une fonctionnalité
manuelle de pièces ou équipements lourds. de charge de batterie destinée à cet usage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT. Les PIÈCES MOBILES peuvent
causer des blessures.
D Prévoir une période de refroidissement ; res-
pecter le cycle opératoire nominal. D S’abstenir de toucher des organes mobiles tels
D Réduire le courant ou le facteur de marche que des ventilateurs.
avant de poursuivre le soudage. D Maintenir fermés et verrouillés les portes,
D Ne pas obstruer les passages d’air du poste. panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-
LES ÉTINCELLES PROJETÉES pannage, faire retirer les portes, panneaux, recouvrements ou
peuvent provoquer des blessures. dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
D Porter un écran facial pour protéger le visage et protection quand l’entretien est terminé et avant de rebrancher
les yeux. l’alimentation électrique.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé- LIRE LES INSTRUCTIONS.
cuter dans un endroit sûr lorsque l’on porte l’équipement ho-
mologué de protection du visage, des mains et du corps. D Lire et appliquer les instructions sur les
D Les étincelles risquent de causer un incendie − éloigner toute étiquettes et le Mode d’emploi avant l’instal-
substance inflammable. lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir- D N’utiliser que les pièces de rechange recommandées par le
constructeur.
cuits imprimés.
D Effectuer l’installation, l’entretien et toute intervention selon les
D Établir la connexion avec la barrette de terre manuels d’utilisateurs, les normes nationales, provinciales et de
avant de manipuler des cartes ou des pièces.
l’industrie, ainsi que les codes municipaux.
OM-273473 Page 7
 LE RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de
FRÉQUENCE (H.F.) risque de provoquer des interférences.
provoquer des interférences.
D L’énergie électromagnétique risque de
D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement
provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et
pements de radio−navigation et de communication, les services l’équipement commandé par ordinateur tel que
de sécurité et les ordinateurs. les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit com-
patible électromagnétiquement.
D Demander seulement à des personnes qualifiées familiarisées avec D Pour réduire la possibilité d’interférence, maintenir les câbles de
des équipements électroniques de faire fonctionner l’installation. soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D L’utilisateur est tenu de faire corriger rapidement par un électricien
D Veiller à souder à une distance de 100 mètres de tout équipement
qualifié les interférences résultant de l’installation. électronique sensible.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
D Effectuer régulièrement le contrôle et l’entretien de l’installation. conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
D Maintenir soigneusement fermés les portes et les panneaux des il incombe à l’utilisateur de prendre des mesures supplémentaires
sources de haute fréquence, maintenir les éclateurs à une distan- telles que le déplacement du poste, l’utilisation de câbles blindés,
ce correcte et utiliser une terre et un blindage pour réduire les l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
interférences éventuelles. de travail.

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
is available as a free download from the American Welding Society at (phone: 800-463-6727, website: [Link]).
[Link] or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: [Link]). tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: [Link]).
al Engineering Documents (phone: 1-877-413-5184, website:
[Link]). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Safe Practices for Welding and Cutting Containers that have Held Com-
Quincy, MA 02269 (phone: 1-800-344-3555, website: [Link]).
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: [Link]). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
[Link] and www. [Link]). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 14501 George Carter Way, Suite [Link]).
103, Chantilly, VA 20151 (phone: 703-788-2700, website:[Link]- Applications Manual for the Revised NIOSH Lifting Equation, The Na-
[Link]). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 [Link]/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs câbles d’un côté et à distance de l’opérateur.
électromagnétiques (CEM) à certains endroits. Le courant issu d’un 3. Ne pas courber et ne pas entourer les câbles autour de votre
soudage à l’arc (et de procédés connexes, y compris le soudage par corps.
points, le gougeage, le découpage plasma et les opérations de 4. Maintenir la tête et le torse aussi loin que possible du matériel du
chauffage par induction) crée un champ électromagnétique (CEM) circuit de soudage.
autour du circuit de soudage. Les champs électromagnétiques produits 5. Connecter la pince sur la pièce aussi près que possible de la
peuvent causer interférence à certains implants médicaux, p. ex. les soudure.
stimulateurs cardiaques. Des mesures de protection pour les porteurs 6. Ne pas travailler à proximité d’une source de soudage, ni
d’implants médicaux doivent être prises: Limiter par exemple tout accès s’asseoir ou se pencher dessus.
aux passants ou procéder à une évaluation des risques individuels pour 7. Ne pas souder tout en portant la source de soudage ou le
les soudeurs. Tous les soudeurs doivent appliquer les procédures dévidoir.
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
En ce qui concerne les implants médicaux :
soudage:
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
1. Rassembler les câbles en les torsadant ou en les attachant avec
points, de gougeage, du coupage plasma ou de chauffage par induc-
du ruban adhésif ou avec une housse.
tion. Si le médecin approuve, il est recommandé de suivre les
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les procédures précédentes.
OM-273473 Page 8
 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.

Safe1 2012−05

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

Safe2 2012−05

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

Safe3 2012−05

Disconnect input plug or power before working on machine.

Safe5 2012−05

Keep your head out of the fumes.

Safe6 2012−05

Use forced ventilation or local exhaust to remove the fumes.

Safe8 2012−05

Use ventilating fan to remove fumes.

Safe10 2012−05

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

Safe12 2012−05

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

Safe14 2012−05

Do not weld on drums or any closed containers.

Safe16 2012−05

OM-273473 Page 9
 Do not remove or paint over (cover) the label.

Safe20 2012−05

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

Safe26 2012−05

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

Safe27 2012−05

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

Safe28 2012−05

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

Safe29 2012−05

Drive rolls can injure fingers.

Safe32 2012−05

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

Safe33 2012−05

Do not discard product with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05

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

Safe38 2012−05

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012−05

V Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
>5min V Safe43 2012−05

OM-273473 Page 10
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.

V Voltage
U1 Primary Voltage I1max Rated Maximum
Supply Current

On Purge By Gas
Degree Of

Voltage Input
IP Protection

Locked
Suitable for Some
Protective Earth
(Ground)
S Hazardous
Locations
Process

Arc Force
I1eff Maximum Effective
Supply Current
Arc Control
Constant Current
Direct Current

X Duty Cycle
I1 Primary Current
(DC)

Input

% Percent
Wire Type
Positive
Three Phase
Trigger Hold On
Indicator Light Constant Voltage
Cold Jog (Inch)
Towards
Workpiece Output
Line Connection

Read Instructions
Wire Feed

Program
Trigger Hold Off

Time Sequence

Alternating
Current (AC) Gas Type

Remote Trigger Hold

Off Indicator Light

Negative

Variable
A Amperage

Inductance
Off

Gas Metal Arc

Arc Force
Welding (GMAW)

Increase
Conventional

U2 Load Voltage
Rated No Load
U0 Voltage (OCV)

I2 Rated Welding
Current

Three Phase Static

Hz Hertz

Frequency Cold Jog (Inch)

Converter-Transfor Away From
mer-Rectifier Workpiece

OM-273473 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 back. 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. 350 Model Specifications

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

. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).

Input Rated Voltage Amperage Max Amperes Input At Rated Load Output 60 Hz, Input Input
Power Welding Range Range Open Three-Phase kVA KW
Output CV Mode CC Mode Circuit
Voltage
DC 230 V 380 V 400 V 460 V 575 V

Three 350 A @ 10-44 V 20-400 A 75 36.7 21.8 20.8 18.8 14.6 14.4 13.8
Phase 34 V DC, (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0.8*) (0.17*)
100%
Duty
Cycle
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.

4-3. 500 Model Specifications

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

. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).

Input Rated Voltage Amperage Max Amperes Input At Rated Load Output 60 Hz, Input Input
Power Welding Range Range Open Three-Phase kVA KW
Output CV Mode CC Mode Circuit
Voltage
DC 230 V 380 V 400 V 460 V 575 V

Three 500 A @ 10-44 V 20-600 A 75 58.7 34.9 33.2 28.9 23.3 23.1 21.9
Phase 40 V DC, (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0.8*) (0.17*)
100%
Duty
Cycle
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.

OM-273473 Page 12
4-4. Dimensions And Weight

Hole Layout Dimensions

A 17-33/64 in. (445 mm) *27-3/16 in.

**28−7/32 in. (691 mm)
B 17-3/8 in. (441 mm) (717 mm)

C 26-11/64 in. (665 mm) A

D
D 16-3/32 in. (409 mm)

E 2-9/32 in. (58 mm) E 24-57/64 in.

(632 mm)
F 15/32 in. (12 mm)
G
15/32 x 1 in.
G
(12 x 25mm)

Weight C B
350 Model:
130 lb (59.4 kg)
350 Model w/Aux Power: 18-3/16 in.
139 lb (63.5 kg) (462 mm)
500 Model: F
151 lb (69 kg)
500 Model w/Aux Power: *Height includes lifting eye
160 lb (73.1 kg) **Length includes E−Stop cover
Lifting Eye Weight Rating:
1000 lb (453 kg) Maximum 907657-tp1

4-5. Environmental Specifications

A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23S 2014−06

B. Temperature Specifications
Operating Temperature Range* Storage/Transportation Temperature Range

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

*Output is derated at temperatures above 104°F (40°C). Temp_2016- 07

4-6. Static Characteristics

The static (output) characteristics of the welding power source can be described as flat during the GMAW process and drooping during the CAC−A
process. Static characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors.
Contact the factory for specific information on the static characteristics of the welding power source.

OM-273473 Page 13
4-7. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
350 Model utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

100% Duty Cycle At 350 Amperes 60% Duty Cycle At 400 Amperes

Continuous Welding 6 Minutes Welding 4 Minutes Resting

Overheating
0 A/V

15
OR
Minutes Reduce Duty Cycle

500 Model

100% Duty Cycle At 500 Amperes 50% Duty Cycle At 600 Amperes

Continuous Welding 5 Minutes Welding 5 Minutes Resting

0 A/V

15
OR
Minutes Reduce Duty Cycle

duty1 4/95 − SA-268 499-A / 268 498-A

OM-273473 Page 14
 SECTION 5 − INSTALLATION
5-1. Selecting A Location

Movement

! Do not move or operate

unit where it could tip.

3
1

OR OR

Location And Airflow

4 ! Special installation may be required

where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
! Do not stack units. Beware of tipping.
1 Lifting Eye
18 in. 2 Lifting Forks
(460 mm) Use lifting eye or lifting forks to move unit.
If using lifting forks, extend forks beyond
opposite side of unit.
3 Hand Cart
Use cart or similar device to move unit.
4 Line Disconnect Device
Locate unit near correct input power supply.

18 in.
(460 mm)

Loc_continuum 2015-07

OM-273473 Page 15
5-2. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02

OM-273473 Page 16
5-3. Connecting Weld Output Cables

! Turn off power before connecting to

Tools Needed: weld output tabs or receptacles.
3/4 in. (19 mm) for output ! Do not use worn, damaged, under-
terminal type connection sized, or repaired cables.
! Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
Ensure all connections are tight.
Tab Connection

. Do not place anything between weld

cable terminal and output tab. Make
sure that the surfaces of the weld cable
terminal and output tab are clean.
1 Negative (−) Output Terminal
2 Positive (+) Output Terminal
3 Correct Weld Cable Connection For
Single Feeder
4 Correct Weld Cable Connection For
2/0 And Larger Double Cables
5 Incorrect Weld Cable Connection
6 Weld Output Terminal Bolt
7 Nut
8 Weld Cable Terminal
9 Output Terminal
Remove supplied nut and bolt from weld
output terminal. Insert bolt through hole in
weld cable terminal and hole in weld output
terminal. Screw nut onto bolt until weld
cable terminal is tight against output termi-
2 1 nal. Torque to 45-55 ft lb (61-75 N·m).

Front View

3 5

6 7
9 8
8
6 9 8 7

2/0 and larger double cables

XX

OM-273473 Page 17
5-4. Remote 10 Wire Feeder Control Receptacle RC2 Information

Socket Socket Information

A +50 Volts DC Common

A H
B +50 Volts DC Common
B I G
J F
C
D E
C Voltage Sense

D +50 Volts DC Power

E +50 Volts DC Power

F ENET Rx −

G ENET Tx −

H Drain

I ENET Tx +

J ENET Rx +
907 657-tp2

5-5. Volt Sense Receptacle RC3 Information

Socket Socket Information

A Not Used

B Volt Sense Negative

C Not Used

D Not Used

907 657-tp2

OM-273473 Page 18
5-6. Peripheral Receptacle RC22 Functions

Socket Socket Information

D C A Output common
E B
R P
F A
S N B Digital output 1 (DO1)
G M
T
H L
J K C Digital output 2 (DO2)

D Digital output 3 (DO3)

E Not Used

F Chassis ground

G Input common

H Request to turn on Touch Sense (DI1)

J Digital input 2 (DI2)

K Digital input 3 (DI3)

L Not Used

M Not Used

N Touched hardware signal

P Not Used

R Not Used

S Not Used

907 657-tp2 T Not Used

5-7. Supplementary Protector CB1, Communication Panel, And E-Stop

1 Ethernet Receptacle
Used for connecting a computer di-
rectly to the power source to ac-
cess configuration web pages.
4 2 Ethernet Receptacle
2 Used for connecting a robot directly
to the power source.
5 3 Supplementary Protector CB1
CB1 protects the wirefeed motor
from overload. If CB1 opens, the
1 wire feeder does not work.

. Press button to reset breaker. If

breaker continues to open,
contact a Factory Authorized
Service Agent.
4 Wireless (WiFi) Antenna
Antenna for connecting to the inter-
net via (WiFi) wireless connection if
selected during configuration.
3
5 E-Stop Receptacle RC24
A short across the two sockets al-
lows unit to weld.

907 657-tp2

OM-273473 Page 19
5-8. Aux Power And CB2 (Optional)
1 115 V AC Receptacle
2 Supplementory Protector CB2
CB2 protects 115 V AC receptacle.

. Press button to reset breaker. If

breaker continues to open,
contact a Factory Authorized
Service Agent.

Ref. 907641−TP1 / 907657-tp2

5-9. Devicenet Receptacle

Socket Socket Information

A Chassis ground.
C
D B +24 volts DC; available current is 1 ampere.
B
A E C +24 volts DC common.

D CAN H.

E CAN L.
Ref. 277971-A

OM-273473 Page 20
5-10. Electrical Service Guide Elec Serv 2014−01

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

. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.

350 Model 60 Hz Three Phase

Input Voltage (V) 230 380 400 460 575
Input Amperes (A) At Rated Output 34.1 20.4 19.2 16.7 13.3
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses 2 50 30 30 25 20
Normal Operating Fuses 3 70 40 35 30 25
Min Input Conductor Size In AWG 4 8 10 12 12 14
119 215 146 193 196
Max Recommended Input Conductor Length In Feet (Meters)
(36) (66) (44) (59) (60)
Min Grounding Conductor Size In AWG 4 8 10 12 12 14

500 Model 60 Hz Three Phase

Input Voltage (V) 230 380 400 460 575
Input Amperes (A) At Rated Output 58.7 34.9 33.2 28.9 23.3
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses 2 70 40 40 35 25
Normal Operating Fuses 3 90 50 50 45 35
Min Input Conductor Size In AWG 4 6 8 8 10 10
142 247 273 237 371
Max Recommended Input Conductor Length In Feet (Meters)
(43) (75) (83) (72) (113)
Min Grounding Conductor Size In AWG 4 8 10 10 10 10

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-273473 Page 21
5-11. Connecting 3-Phase Input Power

3
3 L1 (U)
6 L2 (V)
5
8 L3 (W)
= GND/PE Earth Ground

10

4
4 3
L1
L2 6
Input Power Contactor Connections
9 L3

Side View Of Unit

Tools Needed:

3/8 in.

3/16 in.
input5 2013−04 / 274300-B / 259119-C

OM-273473 Page 22
5-11. Connecting 3-Phase Input Power (Continued)

! Installation must meet all National and 1 Input Power Conductors (Customer 6 Input Conductors L1, L2, L3
Local Codes − have only qualified per- Supplied Cord) Connect input conductors L1, L2, and L3 to
sons make this installation. Select size and length of conductors using welding power source line terminals.
! Disconnect and lockout/tagout input Section 5-10. Conductors must comply with Reinstall top cover on welding power source.
power before connecting input national, state, and local electrical codes. If
applicable, use lugs of proper amperage Disconnect Device Input Power
conductors from unit. Follow estab-
capacity and correct hole size. Connections
lished procedures regarding the in-
stallation and removal of lockout/ Welding Power Source Input Power 7 Disconnect Device (switch shown in the
tagout devices. Connections OFF position)
! Make input power connections to the 2 Strain Relief Kit 274 563 Supplied With 8 Disconnect Device Grounding Terminal
welding power source first. Machine 9 Disconnect Device Line Terminals
! Always connect green or green/yellow Install strain relief of proper size for unit and Connect green or green/yellow grounding
conductor to supply grounding input conductors. Route conductors (cord) conductor to disconnect device grounding ter-
terminal first, and never to a line through strain relief. Tighten strain relief. minal first.
terminal. 3 Welding Power Source Grounding Connect input conductors L1, L2, and L3 to
NOTICE − The Auto-Line circuitry in this unit Terminal disconnect device line terminals.
automatically adapts the power source to the
4 Green Or Green/Yellow Grounding 10 Over-Current Protection
primary voltage being applied. Check input
Conductor Select type and size of over-current protec-
voltage available at site. This unit can be con-
nected to any 3-phase input power between Route green or green/yellow grounding con- tion using Section 5-10 (fused disconnect
230 and 575 VAC without removing cover to ductor through current transducer and con- switch shown).
relink the power source. nect to welding power source grounding Close and secure door on disconnect device.
See rating label on unit and check input volt- terminal first.. Follow established lockout/tagout procedures
age available at site. 5 Welding Power Source Line Terminals to put unit in service.

Input5 2013−04

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-273473 Page 23
 SECTION 6 − RECOMMENDED SETUP PROCEDURES

6-1. Welding Circuit

. Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics.

1 Welding Power Source

. Appearance of actual unit may differ from that shown. 2 Electrode Cable
3 Feeder Cable
Standard Welding Circuit 4 Work Cable
5 Voltage Sensing Lead
ECL 6 Robot
7 Workpiece
In pulse welding applications using
inverter power sources, cable
resistance can result in less than
satisfactory performance. In most
cases, a welding circuit length of 50 ft
(15 m) or less will provide satisfactory
performance with a standard welding
Gun circuit connection.
Travel
The length of a welding circuit is
determined as follows:
Welding Circuit = Electrode Cable
Length (ECL) + Work Cable Length
WCL
(WCL) + Workpiece Length (WL)
See Section 5-2 for weld cable size.
Variations in welding processes and
welding circuit resistance can affect
apparent voltage at the welding arc.
WL Voltage sensing can improve welding
performance by providing accurate
Current Flow Path feedback to the welding power source.
It is important to connect the voltage
sensing lead as near to the weld as
Large Weld Structure possible, but not in the return current
path.

ECL

WCL

WL

250 489-B

Current Flow Path

OM-273473 Page 24
6-2. Arranging Welding Cables To Reduce Welding Circuit Inductance
. Appearance of actual unit may differ from that shown. 1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable
Bad 1 5 Voltage Sensing Lead
6 Robot
6 7 Workpiece
2 3 The arrangement of the cables has an
effect that is significant to the welding
properties. As an example, Accupulse
and RMD welding processes can
produce high welding circuit inductance
depending on cable length and
arrangement. This can result in limited
current rise during droplet transfer into
the welding puddle.
5
The Vsense option can be turned On or
Off in the Setup menu or by using the
4 web pages. The electrode sense lead is
contained in the feeder control cable
and compensates for voltage drop in all
semi-automatic processes when the
Vsense option is On . The work sense
7 lead connects to the Axcess welding
power source 4-pin connector located
above the negative output terminal. This
work sense lead compensates for work
cable voltage drop when connected to
Better 1 the welding power source when the
Vsense option is On.
Do not coil excess cables. Use cables
that are the appropriate length for the
6 application. Whenever using long weld
cables [longer than 50 ft (15 m)] try to
arrange positive and negative weld
cables together to reduce the magnetic
field surrounding the cables. Avoid
2 coupling the feeder and work sense
3 leads with the weld cables.

Best 1

2
3

4
5

7 250 503-B

OM-273473 Page 25
6-3. Using Multiple Welding Power Sources

. Appearance of actual unit may differ from that shown.

1
1

2
2
4

5 4
5
6

Gun
Travel

Current Flow Path

250 504-B

1 Welding Power Source possible, but not in the return current path. Arc blow occurs primarily during the
2 Electrode Cable welding of steel or ferromagnetic metals.
Connect voltage sensing lead at the end of
the weld joint. Weld current will take the path of least
3 Feeder Cable resistance, but not always the most direct
4 Work Cable The direction of the welding path should be path through the workpiece to the work
away from the work cable connections. lead connection. The most intense magnet
5 Voltage Sensing Lead
Connect work clamp at the beginning of the force will be around the arc due to a
6 Robot difference in resistance for the magnetic
weld joint.
7 Workpiece path in the base metal. The work clamp
Each welding gun should have its own connection is important and should be
Each welding power source should have a source of shielding gas. Use a separate placed at the starting point of a weld. It is
separate work cable connection to the shielding gas regulator and shielding gas recommended to have as short of an arc as
workpiece. Do not stack or join work connection for each welding gun. possible so that there is less of an arc for
cables together at the workpiece. This is
Arc blow is the deflection of a welding arc the magnetic forces to control. Conditions
very important for pulse welding applica-
from its normal path due to magnetic affecting the magnetic force acting on the
tions.
forces. It will adversely affect the arc vary so widely that the reference here
It is important to connect the voltage appearance of a weld, cause excessive is only about cabling connections and arc
sensing lead as near to the weld as spatter, and impair the quality of a weld. preferences.

OM-273473 Page 26
6-4. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs
A. Bad Setup

. Appearance of actual unit may differ from that shown.

3
2

4 5
2
4
3
6

Current Flow Path

250 512-B

1 Welding Power Source 7 Workpiece across the workpiece will not be measured
2 Electrode Cable correctly for the voltage feedback signal.
This arrangement is a bad setup due to Voltage feedback to the welding power
3 Feeder Cable
sensing leads being directly in the current sources will not be correct at either sense
4 Work Cable flow path of the welding arc. Interaction lead and result in poor arc starts and arc
5 Voltage Sensing Lead between welding circuits will affect voltage quality.
6 Robot drop in the workpiece. The voltage drop

OM-273473 Page 27
B. Better Setup

. Appearance of actual unit may differ from that shown.

3
2 1

6 5
7 2

6 5

Current Flow Path

250 513-B

1 Welding Power Source 6 Robot the welding power sources. The most
2 Electrode Cable accurate voltage sensing may not be
7 Workpiece achieved due to voltage drops in the
3 Feeder Cable
workpiece. This may require
4 Work Cable This arrangement is a better setup for compensation in the welding parameters.
5 Voltage Sensing Lead supporting separate voltage feedback to

OM-273473 Page 28
C. Best Setup

. Appearance of actual unit may differ from that shown.

3
2 1
5

6 7 4
2
5

4
6

Current Flow Path

250 515-B

1 Welding Power Source 5 Voltage Sensing Lead This arrangement is the best setup for
2 Electrode Cable proper voltage sensing at the workpiece.
6 Robot Voltage feedback to the welding power
3 Feeder Cable sources will more accurate and result in
4 Work Cable 7 Workpiece reliable arc starts and better arc quality.

OM-273473 Page 29
6-5. Earth Grounding
When using a robot or any programmable controls, it is necessary to connect equipment to a good earth ground. Grounding helps eliminate electrically
generated noise from corrupting processing data or the potential damage to sensitive electrical components. Electrical noise is an issue anytime high
frequency TIG equipment or inverter type power supplies are used in the area. A method for checking for a good earth ground is shown below. Also, be
sure to a good connection to the earth ground.

110 Volts AC

100W Light Bulb

Neutral
V

1 Volt  1 W

Earth Ground
Being Measured

Measuring Facility (Earth) Ground Resistance

The resistance of an earth ground can be measured using a 100W light bulb, an ac voltmeter and a 110 volts AC electrical drop. As shown in the circuit,
the 110 volts AC (hot) supply and the 100W light bulb approximate a 1 ampere current source when the light bulb circuit is completed by connecting to
the earth ground. The AC voltmeter, referenced to the AC neutral line, can then be used to measure the voltage rise due to the 1 ampere current source
through earth ground. Each volt of rise on the earth ground represents 1 ohm of resistance. A resistance of less than 10 ohms at the earth ground should
be adequate.

OM-273473 Page 30
 Input Power
IMPORTANT: DO NOT mount anything to robot control cabinet. Supply Line

Line Disconnect Switch Box

For Input Power To Fixture Existing
Positioning And Peripheral Input Power
Equipment Supply Ground

Make Separate Equipment

Earth Ground Using A Minimum
Of No. 3 Gauge Copper Braided
Cable That Provides A Resistance
Value Less Than 100 Ohms Between
The Component Connection And
The Ground Wire

Line
Input Power Disconnect Input Power
Supply Line Switch Box Supply Line
Insulating
Plate
Under Robot
Make Ground
Lead 5 ft. (1.5 m) Line
To 10 ft. (3 m) Longer Disconnect
Existing And Coil It Inside
Input Power Switch Box
Robot Control
Supply
Ground Existing
Work Weld Input Power
Cable Supply Ground
Worktable
Robot
15 ft. Control
Welding (4.5 m) If Using
Power Conduit,
Source Isolate It
From Robot
Control
Cabinet

10 ft. (3 m)
Minimum 5 ft. Insulating Liner
5 ft. (1.5 m) Strips Under Both
(1.5 m) Support Channels
Use Proper Size Input And Ground Customer Supplied Driven Ground Rod Use Proper Size Input And Ground
Conductors For The Input Power Or Separate Earth Ground Connection Conductors For The Input Power
Supply Line Voltage Less Than 100 Ohms To Building Ground Supply Line Voltage

Figure 9-1. Earth Ground Connections To Stationary Robot System Components SB-136 221-A

OM-273473 Page 31
6-6. 30 Points Of Mechanics In MIG Welding 30 Pts MIG − 2014-09

Primary Power
S Check primary power connection at line disconnect switch or receptacle and/or cord plug.
S Check primary power connection at welding power source.

Secondary Power
S Check secondary weld output connections at welding power source.
S Inspect condition and routing of positive weld cable to wire drive motor.
S Check connection of positive weld cable to wire drive motor.
S Inspect condition and routing of negative weld cable to fixture.
S Check connection of negative weld cable to fixture.
S Inspect condition of any rotary grounds, grounding shoes or other auxiliary grounds.
S Check installation, routing and condition of welding gun.

Shielding Gas
S Check gas hose connection to shielding gas supply regulator.
S Check shielding gas flow rate.
S Check gas hose routing.
S Check gas hose connection at wire drive housing.
S Check gun connection at wire drive and be sure O−rings seal at drive housing.
S Check condition of gas diffuser.
S Check condition of nozzle.
S Check O-ring for proper sealing at nozzle.

Welding Wire
S Inspect condition of de-reeler. Check for wear at quick-connect coupling and replace if necessary.
S Check placement of payoff pack or drum for smooth feed path.
S Inspect condition and routing of input conduit.
S Check installation of quick-connect coupling at rear of wire drive so that it does not contact drive rolls. Check for wear and replace if necessary.
S Check drive rolls and replace if worn.
S Check for drive roll tension setting.
S Check intermediate guide for proper size to match wire size and replace if worn.
S Check for proper length of liner at both ends and be sure it is cut without burrs.
S Check liner for proper size to match wire size.
S Check liner for wear and clean out to prevent plugging.
S Check contact tip for proper size to match wire size.
S Check contact tip for wear and change at regular intervals.
S Check contact tip for a tight fit and secure installation at gun.

OM-273473 Page 32
6-7. Arc Blow
Arc blow is the deflection of the welding arc from its normal path due to magnetic forces. This condition is usually encountered in direct current welding of
magnetic materials, such as iron and nickel. Arc blow can happen in alternating current welding under certain conditions, but these cases are rare and
the intensity of the arc blow is always less severe. Direct current flowing through the electrode and base metal will set up a magnetic field around the
electrode. This magnetic field tends to deflect the arc to the side at times, but usually the arc deflects either forward or backwards along the joint.

Back blow is encountered when welding toward the work cable connection on a workpiece near the end of a joint or into a corner. Forward blow is
encountered when welding away from the work cable connection on a workpiece at the start of a joint. In general, arc blow is the result of two basic
conditions:
1. The change of current flow direction as it enters the work and is conducted toward the work cable.
2. The asymmetric arrangement of magnetic material around the arc, a condition that normally exists when welding is performed near the end of
ferromagnetic materials.

Although arc blow cannot always be completely eliminated, it can be controlled or reduced to an acceptable level through knowledge of the two condi-
tions listed above.

Except in cases where arc blow is unusually severe, certain steps can be taken to eliminate or reduces its severity. Some or all of the following steps
may be necessary:
* Place work cable connection as far as possible from joints to be welded.
* If back blow is the problem, place the work cable connection at the start of the joint to be welded and weld toward a heavy tack weld.
* If forward blow is the problem, place the work cable connection at the end of the joint to be welded.
* Position electrode angle so that arc force counteracts arc blow.
* Use the shortest possible arc that maintains good welding practices (this helps arc force to counteract arc blow).
* Reduce welding current if possible.
* Weld toward a heavy tack weld or runoff tab.
* Use the back step sequence of welding.
* Change to an AC welding operation which may require a change in electrode classification.
* Wrap the work cable around the workpiece in the direction that sets up a magnetic field to counteract the magnetic field causing the arc blow.

Notes

OM-273473 Page 33
6-8. Basic Welding Troubleshooting
Listed below are some problems, causes and remedies related to welding operations; however, this list does not contain every possible condition that
could be encountered in welding.

Trouble Probable Cause Remedy

No weld output; unit completely Line disconnect switch in Off position. Place switch in On position.
inoperative.
Power source switch in Off position. Place switch in On position.
Primary power fuse blown or circuit breaker Replace fuse or reset circuit breaker and check in-
tripped. put voltage.
Weld output is present, but wire stops Wire feeder protective fuse blown or circuit breaker Replace fuse or reset circuit breaker and find over-
feeding while welding. tripped. load condition.
Wire feeder drive rolls misaligned. Align drive rolls.
Wrong size drive rolls. Replace with proper size drive rolls.
Too much or too little drive roll pressure. Adjust drive roll pressure.
Too much tension set at wire spool. Reduce wire spool tension.
Restriction in unspooler or drum adapter. Replace unspooler or repair restriction.
Feeder motor burnt out. Test motor and replace if necessary.
Gun liner dirty or restricted. Remove gun liner and clean or replace.
Wrong type or size of liner. Install proper size liner.
Broken or damaged gun or torch. Replace faulty parts.
Contact tip opening restricted. Replace contact tip.
Wrong size or type of contact tip. Replace with proper size and type contact tip.
Sharp bends or kinks in gun cable or liner. Straighten gun cable and/or replace liner.
Gun overheating. Use gun with proper amperage rating.
Wrong size wire. Match wire size to liner and contact tip.
Guides rubbing on drive rolls. Adjust or position guides properly.
Drive rolls jammed. Remove foreign object from gears.
Motor cable disconnected or damaged. Connect, repair or replace motor cable.

OM-273473 Page 34
 Trouble Probable Cause Remedy
Porosity in weld. Dirty base metal, heavy oxides, mill scale, oil, etc. Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Regulator/flowmeter faulty. Adjust or replace regulator/flowmeter.
Gas cylinder valve closed. Open gas cylinder valve.
Gas regulator diaphragm defective. Replace regulator.
Flowmeter cracked or broken. Repair or replace flowmeter.
Gas hose disconnected or leaking. Connect or replace gas hose.
Too much or too little gas flow. Adjust for proper gas flow.
Moisture in shielding gas. Replace gas cylinder or supply.
Wrong gas for wire type or transfer mode. Use correct shielding gas.
Feeder gas solenoid faulty. Replace solenoid.
Gun or outlet cable leaking. Repair or replace faulty parts.
Wire feed speed setting too high. Reduce wire feed speed.
Contact tip extends too far out of nozzle. Adjust or replace parts (max distance should not
exceed 1/8 in (3.2 mm).
Nozzle to work distance too large. Reduce nozzle to work distance.
Incorrect gun or torch angle. Set proper gun angle (porosity or dirty welds mean
gun angle is too large).
Nozzle restriction. Clean off spatter or remove restriction.
Breeze or drafts in weld zone. Shield weld zone from drafts.
Low shielding gas cylinder pressure. Replace gas cylinder.
Gas leak at gun to feeder connection. Properly install gun or replace O-rings at gun
connector.
Excessive spatter. Voltage set too high. Reduce voltage setting (reduce trim or arc adjust
for pulse welding).
Incorrect gun or torch angle. Set proper gun angle.
Too much or too little gas flow. Adjust for proper gas flow.
Wrong gas for wire type or transfer mode. Use correct shielding gas.
Wrong electrode wire type or size. Use proper electrode wire.
Wrong inductance setting. Adjust inductance.
Electrode wire dirty or old. Replace with new electrode wire.
Oily or dirty base metal. Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Excessive wire stick-out or nozzle to work distance Adjust wire stick-out or reduce nozzle to work
too great. distance.
Wrong transfer mode. Set proper transfer mode.
Travel speed too slow. Increase travel speed so that arc is on leading edge
of weld puddle.

OM-273473 Page 35
 Trouble Probable Cause Remedy
Wandering, hunting or erratic arc. Restriction in unspooler or drum adapter. Replace unspooler or repair restriction.
Dirty or worn gun liner or inlet cable. Remove gun liner or inlet cable and clean or re-
place.
Sharp bends or kinks in gun cable or liner. Straighten gun cable and/or replace liner.
Loose or worn contact tip. Tighten or replace contact tip.
Wrong size or type of contact tip. Replace with proper size and type contact tip.
Gun overheating. Use gun with proper amperage rating.
Loose power cables or other electrical Tighten, repair or replace connections or cables,
connections. also check all rotary or brush type connections.
Incorrect gun or torch angle. Set proper gun angle.
Too much or too little gas flow. Adjust for proper gas flow.
Moisture in shielding gas. Replace gas cylinder or supply.
Wrong gas for wire type or transfer mode. Use correct shielding gas.
Wrong program selection for pulse welding. Make proper program selection.
Improper or unsteady analog command from robot Check signal from robot controller (as a trouble-
controller. shooting aid go to power source control of voltage
and wire speed).
Gun or outlet cable leaking. Repair or replace faulty parts.
Incorrect nozzle to work distance. Set proper distance [3/8 in to 5/8 in (9.5 to 15.9 mm)
for short arc, 5/8 in to 1 in (15.9 to 25.4 mm) for
pulse welding, and 3/4 in to 1-1/4 in (19.1 to 31.8
mm) for spray welding].
Voltage sensing leads open or shorted. Repair or replace voltage sense leads.
High frequency noise in the area. Be sure proper grounding methods are followed
when TIG or plasma equipment is used in the area.
Arc blow. See Section 6-7.
Drive motor tachometer or motor cable open or Check drive motor tachometer and cables, and re-
shorted. pair or replace.
Wrong size drive rolls. Replace with proper size drive rolls.
Too much or too little drive roll pressure. Adjust drive roll pressure.
Welding wire burns back to contact tip at Restriction in wire feed system. Check inlet cable, gun liner and wire guides.
the start of a weld.
Worn drive rolls. Replace drive rolls.
Wrong size drive rolls. Replace with proper size drive rolls.
Improper start parameters. Adjust start parameters.
Worn contact tip. Replace contact tip.
Wrong size or type of contact tip. Replace with proper size and type contact tip.
Not enough cast in welding wire. Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip Restriction in wire feed system. Check inlet cable, gun liner and wire guides.
during welding.
Worn drive rolls. Replace drive rolls.
Wrong size drive rolls. Replace with proper size drive rolls.
Too much or too little drive roll pressure. Adjust drive roll pressure.
Worn contact tip. Replace contact tip.
Wrong size or type of contact tip. Replace with proper size and type contact tip.
Not enough cast in welding wire. Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip at Welding power source output not shutting off. Make sure all switches are in correct position,
the end of a weld. repair power source if necessary.
Burnback setting too high or too long. Adjust burnback setting or turn off completely.

OM-273473 Page 36
 SECTION 7 − OPERATION

7-1. Operator Controls

1 Power Switch
Turns unit On or Off.
2 Power On LED
Power LED illuminates when unit is
energized.
3 Output On LED
Output LED illuminates when weld
output is energized.
4 Error LED
On Solid−
Unit has overheated and weld out-
put has been disabled. Allow unit to
cool to operating temperature. Er-
ror LED will turn off and welding
may resume.
Blinking−
A system error has occurred. Use
the User Interface to determine the
1 source of the error as well as possi-
ble solutions. Follow on-screen in-
structions to clear the error. When
the error has been cleared the Error
LED will stop blinking and welding
may resume.

. After turning unit off, wait until

Power ON LED is off before
turning unit back on. Cycling
power too quickly can cause
software issues on power up.

Ref. 257195-G

OM-273473 Page 37
7-2. User Interface

1 10 13 12 18 14 15 16 8

17

11
20

7
6

19

Ref. 266 061-B

5

OM-273473 Page 38
7-3. Description Of Front Panel Controls (See Section 7-2)

1 Memory Display button. Press the button to select options 13 Voltage Indicator
The Memory display shows the active weld available in the LCD display
LED illuminates to show that the voltage
program. The range is from 0001 to 9999. 7 Values/Parameters LCD Display function is active.
2 Memory/Variable Adjustment Knob This display shows all values and parame- 14 Synergic Mode Active Indicator
ters that have been selected using the Soft
Use this knob to select a program number LED illuminates to show that a synergic
Key buttons and the Scroll knob and Save/
or increase/decrease the variable shown in weld process is active.
Select button.
the Memory display.
8 Amperage/Wire Feed Speed Display 15 Amperage Indicator
3 Arc Control Button
This display shows amperage, or wire feed LED illuminates to show that a SMAW,
The Arc Control button is process depen- speed depending on the process selected. GMAW or CAG process is selected. Values
dent. It allows user to change the variable appear on the Voltage/Arc Length/Induc-
that appears on the Values/Parameters dis- 9 Amperage/Wire Feed Speed/Material
Thickness Adjustment Knob tance/Arc Adjust/RMD display.
play, such as inductance, DIG, RMD (ball
size) or trim. The range can be +/− depend- Use this knob to increase/decrease amper- 16 Wire Feed Speed Indicator
ing on the process. age, wire feed speed, or material thickness LED illuminates to show that a GMAW or
depending on the process selection. These GMAW-P weld process is selected. Values
4 Memory 1-8 Buttons And LEDs
values appear on the Amperage/Wire Feed appear on the Amperage/Wire Feed Speed/
Use these buttons to select a stored Speed/Material Thickness display. Material Thickness display.
program from the weld program library data.
10 Voltage/Arc Length/Inductance/Arc 17 Material Thickness Indicator
The LED will indicate which program is
Adjust/RMD Display
selected and active. This feature will be functional in a later soft-
The Variables/Parameters display will This display shows voltage, arc length, in-
ware release.
show weld program library summary data ductance, arc adjust or RMD depending on
for the selected program. the process selected. 18 Output ON Indicator
5 Soft Key Buttons 11 Voltage/Arc Control Adjustment Knob LED illuminates to show that open circuit
Use this knob to increase/decrease voltage voltage is present at the weld output termi-
Use these buttons to navigate the menus nals.
appearing in the LCD display or arc length depending on the process se-
lection. These values appear on the 19 USB Port
6 Scroll Knob And Select/Save Button Voltage/Arc Length/Inductance/Arc Adjust/
Rotate this knob to scroll available options RMD display. Use this port for all USB related functions
or increase/decrease the variable shown in 12 Arc Length Indicator 20 Parameter Lock Indicator
the LCD display.
LED illuminates to show that arc length LED illuminates to show weld parameters
Pressing this knob acts as a Select/Save function is active. are locked and active.

* Disabled or not available.

OM-273473 Page 39
 SECTION 8 − CONFIGURATION
8-1. Accessing Configuration Web Pages
To access the power source configuration webpages you will need the optional communication panel (See Section 5-7). Connect a PC directly to the
jack on the communication panel with a CAT5 or CAT6 Ethernet cable.

Enter the default IP address, [Link], into a web browser and the welder configuration web pages will open to the Home screen.

8-2. Home Screen

9 7

1 Navigation Bar Displays the program number, process, wire 7 Last Weld
Select Home, Setup, Arc Management, Data size and alloy, and gas. Edit button allows Displays the voltage and amperage used dur-
Management, or Help screens. these parameters to be changed. ing the last weld made.
2 Information Bar 5 Weld Outputs (Live)
8 Productivity
Displays general information on power Displays the weld output conditions of the
source, location, asset number, serial num- power source and feeder in real time. Displays arc time, the amount of wire used,
ber, and display language. and the amount of wire remaining.
6 Commands
3 Power Source Information Displays current user changeable com- 9 Active Error
Displays power source information. Edit but- mands. Depending on the weld process being Displays any active error messages. View
ton allows these parameters to be changed. used these commands will vary. Edit button Error Log button will display a list of previous
4 Active Program allows parameters to be changed. errors and the time at which they occurred.

OM-273473 Page 40
8-3. Setup Screen
2
1

8
7

11

10

12

14

13

15

1 Information Bar 6 Data Connections 11 Wire Spool

Displays general information on welding pow- Displays which data connections are enabled Displays wire type, spool size, and amount of
er source, location, asset number, serial num- or disabled. wire remaining on the spool. Edit button allows
ber, and display language. wire information to be changed or reset.
7 Region
2 Purge Time 12 Weld Cable Setup
Displays the length of time gas will flow when Displays current region. Edit button allows re-
the purge button is pressed. Edit button allows gion to be changed. Displays length and diameter of positive and
time length to be changed. 8 Status negative weld leads, torch, and voltage feed-
back (VFB) method that are selected. Edit but-
3 Enabled Errors Displays the status of Insight software. Edit ton allows these parameters to be changed.
Displays which system errors are enabled. button allows that status to be changed.
Click Edit to enable or disable system errors. 13 Robot Options
9 WiFi Settings
4 Jog Speed Displays current robot connectivity options.
Displays the minimum and maximum Jog Edit button allows user to change WiFi Edit button allows robot options to be
Settings. changed.
speeds in inches per minute (IPM). Edit button
allows minimum and maximum jog speed set- 10 Auto Thread 14 Dry Run
ting to be changed for forward and reverse jog. Displays the Load Rate in inches per minute
5 Ethernet Settings (IPM) and Torch Length (Inches) to determine
Edit button allows user to change connectivity the length of time for Auto Threading. Edit but- 15 Relay I/O
settings. ton allows these parameters to be changed.

OM-273473 Page 41
8-4. Arc Management Screen

1 2 3

6
4

1 Active Program 3 Weld Sequence 5 Program Enable

Displays the program number, process, wire Displays active weld sequence parameters.
size and alloy, and gas. Edit button allows Edit button will allow user to select which pro-
Edit button allows changes to these parame- grams are available for use.
these parameters to be changed. ters.
2 Commands 6 Weld Processes
4 Lock Status
Displays current user changeable commands.
Depending on the weld process being used Displays the current status of system locks. Displays available weld processes. Edit but-
these commands will vary. Edit button allows Edit button allows the lock configuration to be ton allows processes to be enabled or dis-
parameters to be changed. changed. abled.

OM-273473 Page 42
8-5. Data Management Screen

1 2 3

4 5 6

1 Productivity Factory Reset button will take user to a Facto- 5 System Log
Displays tarc time and wire used in inches and ry Reset screen. Read and follow all instruc- Displays the last entry into the system log.
pounds. Click Reset Data to reset productivity tions on Factory Reset screen to perform a
Factory Reset. View button displays a list of the entries made
data.
to the system log and the time at which they
2 Lifetime Information 4 Error Log occurred.
Displays total arc time, arc starts, and wire Displays the last error experienced by the 6 Wire Usage
used over lifetime of unit. system.
Displays the amount of wire used, the amount
3 Software Information View button displays a list of previous errors remaining, and the date the spool was started.
Displays the software revision. and the time at which they occurred. Click Reset Data when starting a new spool.

8-6. Help Screen

. The Help Screen contains

three drop down menus
which contain the features
on the Setup, Arc Manage-
1 3 ment and Data Management
2 screens.
1 Setup Information
Drop−Down Menu

2 Arc Management
Drop−Down Menu

3 Data Management
Drop−Down Menu

OM-273473 Page 43
 SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Routine Maintenance

! Disconnect power . Maintain more often

before maintaining. during severe conditions.

n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent

Every l Unreadable Labels ~ Weld Terminals nl Weld Cables nl Gun Cables

3
Months

nl Cords nl Cracked Parts ~ Weld Connections n Tighten Weld Cable

Connections
Every
6 OR
Months
~ Inside Unit

9-2. Blowing Out Inside Of Unit

! Do not remove case when

blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers.

907657-tp1

OM-273473 Page 44
9-3. Error Code Troubleshooting Description And Tables

ERR BTN STUK

2 ERROR
3
4
Button on UI stuck

Make sure all buttons are clear

If error persists, please contact support.

Logs

5
Ref. 266 061-B

1 LED Display Message ERROR- The system has experienced a 3 LCD Display Message
fault that must be addressed before contin- Provides more information about the mes-
Displays a short message describing the uing use. sage being displayed.
error or where the error is occurring. Some MESSAGE- No fault has occurred, but 4 LCD Solution Message
messages may represent multiple different some action must be taken before resum- Describes the action needed to clear the
errors. For more specific error information ing use of the welding system. For message or fault being experienced.
see the LCD Display Message. instance, input power may need to be
5 Logs Soft Key
cycled after loading new software.
Pressing the Logs soft key will take the us-
2 Message Type
WARNING- There is something that er to the Logs Menu. From the Logs Menu
should be addressed before continuing. it is possible to access the Error Log. The
There are three types of messages that will For instance, the volt sense lead connec- LCD Error Log Messages are stored in the
be displayed. tion has been lost. Error Log.

OM-273473 Page 45
 LED Display Message LCD Solution LCD Error Log
LCD Display Message
Message Type Message Message
WELD WAIT ERROR Unit was not ready for a weld se- Press button to clear error Weld Wait Error
quence
ERR OVERTEMP ERROR Welding power source has overheated Allow unit too cool then cycle Overtemp Error
power
E STOP ERROR Emergency stop activated Reset the emergency stop E Stop
button
OVER CURRENT ERROR Welding power source primary draw Check input primary then cy- Primary Overcurrent
too high cle power
CYCLE POWER MESSAGE The unit requires a power cycle Cycle power on the power Cycle Power Error
source
OVER POWER ERROR
SLF TST ERR ERROR Welder failed self test Cycle power on the power Self Test Error
source
ERR INPT PWR ERROR Input Power Problem Ensure your primary voltage is Input Power Problem
correct
ERR FDR ERROR Feeder Power Problem Cycle power on the power Feeder Power Problem
source
ERR AUX PWR ERROR AUX Power Problem Cycle power on the power AUX Power Problem
source
ERR THERM ERROR Thermal System Problem Cycle power on the power Thermal System Problem
source
ERR PWR SRC ERROR Welder Power Source Problem Cycle power on the power Power Source Problem
source
ERR WFS ERROR Actual WFS does not match command Press button to clear error Wire Speed Error
ERR STRT ERROR Trigger held too long without arc Press button to clear error Arc Start Error
ERR STOP ERROR Potential obstruction in wire feed sys- Check wire feed and wire Arc Stop Error
tem drive systems
ERR GAS FLW ERROR No gas flow to the gun Check gas connections Gas Flow Error
ERR COOL FLW ERROR No coolant flow in water system Check water cooling system Coolant Flow Error
ERR GND CRNT ERROR Weld current detected in earth ground Check and repair feeder weld Earth Ground Current Error
connections
ERR WIR STUK ERROR Wire stick to workpiece at the end of Break/Cut wire away from Wire Stuck Error
the weld workpiece
ERR ARC ERROR Arc Outage occurred Check wire feeder and power Arc Outage Error
source
ERR TRG STUK ERROR Trigger held during power up Release trigger and cycle Trigger Stuck Error
power
ERR SOFTWARE ERROR Incompatible software detected in the Update software Incompatible Software Error
system
ERR FEEDER ERROR Feeder peripheral malfunction Cycle power on the power Feeder EEPROM Error
source
ERR FEEDER ERROR Feeder peripheral malfunction Cycle power on the power Feeder USART1 Error
source
ERR COMM FDR ERROR Feeder Lost Comms to Arc Controller Check the control cable Feeder lost comms to AC
ERR FDR PWR ERROR Feeder power fault Cycle power on the power Feeder bus overcurrent error
source
ERR FDR PWR ERROR Feeder power fault Cycle power on the power Feeder bus current fault
source
ERR FDR RLY ERROR Feeder power relay stuck open Cycle power on the power Feeder relay stuck open
source
ERR FDR ETH ERROR Feeder Ethernet switch malfunction Cycle power on the power Feeder Ethernet switch error
source
ERR FEEDER ERROR Feeder peripheral malfunction Cycle power on the power Feeder USART3 Error
source
ERR FEEDER ERROR Feeder peripheral malfunction Cycle power on the power Feeder USART2 Error
source
ERR FEEDER ERROR Feeder peripheral malfunction Cycle power on the power Feeder SPI2 Error
source
ERR FDR TACH ERROR Feeder has lost tachometer wire Feeder lost tach signal error
speed feedback
OM-273473 Page 46
 LED Display Message LCD Solution LCD Error Log
LCD Display Message
Message Type Message Message
ERR BTN STUK ERROR Button on UI stuck Make sure all buttons are UI Button Stuck
clear
ERR COMM UI ERROR UI Lost Comms to the Sequencer Check the control cable UI lost comms to Seq
FACTORY RST ERROR Factory Reset Complete Cycle power on the power Factory Reset
source
UNUSED 218 ERROR Unused Error #218 Cycle power on the power Unused Error #218
source
ERR INPT PWR ERROR Must use three phase primary power Check primary connections Single Phase Error
ERR INPT PWR ERROR Primary input voltage too high Check primary connections High Input Voltage Error
ERR INPT PWR ERROR Primary input voltage too low Check primary connections Low Input Voltage Error
UNUSED 222 ERROR Unused Error #222 Cycle power on the power Unused Error #222
source
ERR FEEDER ERROR Feeder input voltage too high Cycle power on the power Feeder Voltage High Error
source
ERR FEEDER ERROR Feeder input voltage too low Cycle power on the power Feeder Voltage Low Error
source
UNUSED 225 ERROR Unused Error #225 Cycle power on the power Unused Error #225
source
ERR AUX PWR ERROR Too much current draw from AUX Cycle power on the power AUX Power Overcurrent Error
power port source
ERR AUX PWR ERROR AUX power module overheated Cycle power on the power AUX Power Overtemp Error
source
ERR AUX PWR ERROR AUX power voltage too high Cycle power on the power AUX Voltage High Error
source
ERR AUX PWR ERROR AUX power voltage too low Cycle power on the power AUX Voltage Low Error
source
UNUSED 230 ERROR Unused Error #230 Cycle power on the power Unused Error #230
source
ERR THERM 1 ERROR Thermistor 1 overtemp Allow welder to cool then cy- THERM1 Overtemp Error
cle power
ERR THERM 2 ERROR Thermistor 2 overtemp Allow welder to cool then cy- THERM2 Overtemp Error
cle power
ERR THERM 3 ERROR Thermistor 3 overtemp Allow welder to cool then cy- THERM3 Overtemp Error
cle power
ERR THERM 1 ERROR Thermistor 1 shorted Cycle power on the power THERM1 Shorted Error
source
ERR THERM 2 ERROR Thermistor 2 shorted Cycle power on the power THERM2 Shorted Error
source
ERR THERM 3 ERROR Thermistor 3 shorted Cycle power on the power THERM3 Shorted Error
source
ERR THERM 1 ERROR Thermistor 1 open Cycle power on the power THERM1 Open Error
source
ERR THERM 2 ERROR Thermistor 2 open Cycle power on the power THERM2 Open Error
source
ERR THERM 3 ERROR Thermistor 3 open Cycle power on the power THERM3 Open Error
source
UNUSED 240 ERROR Unused Error #240 Cycle power on the power Unused Error #240
source
ERR PWR SRC ERROR Invalid device configuration Cycle power on the power Invalid Power Source Config
source
ERR PWR SRC ERROR Output current sensor malfunction Cycle power on the power Output Current Sensor Error
source
ERR PWR SRC ERROR Inverter −15V power supply out of reg- Cycle power on the power Inverter −15V Power Error
ulation source
ERR PWR SRC ERROR Inverter +15V power supply out of reg- Cycle power on the power Inverter +15V Power Error
ulation source
ERR PWR SRC ERROR Invalid inverter device configuration Cycle power on the power Invalid Inverter Config
source
ERR PWR SRC ERROR Inverter primary CT error Cycle power on the power Inverter Primary CT Error
source
OM-273473 Page 47
 LED Display Message LCD Solution LCD Error Log
LCD Display Message
Message Type Message Message
ERR PWR SRC ERROR Boost fault Cycle power on the power Boost Fault Error
source
ERR PWR SRC ERROR Boost contactor error Cycle power on the power Boost Contactor Error
source
ERR PWR SRC ERROR Boost CS1 current error Cycle power on the power Boost CS1 Error
source
ERR PWR SRC ERROR Boost CS2 current error Cycle power on the power Boost CS2 Error
source
ERR PWR SRC ERROR Boost CS3 current error Cycle power on the power Boost CS3 Error
source
ERR PWR SRC ERROR Boost CS4 current error Cycle power on the power Boost CS4 Error
source
ERR PWR SRC ERROR Boost current balance error Cycle power on the power Boost Current Balance Error
source
ERR PWR SRC ERROR Boost overcurrent error Cycle power on the power Boost Overcurrent Error
source
ERR PWR SRC ERROR Boost precharge error Cycle power on the power Boost Precharge Error
source
ERR PWR SRC ERROR Boost bus balance error Cycle power on the power Boost Bus Balance Error
source
ERR PWR SRC ERROR Boost bottom bus cap voltage high Cycle power on the power Boost Bottom Bus Cap V High
source
ERR PWR SRC ERROR Boost top bus cap voltage high Cycle power on the power Boost Top Bus Cap V High
source
ERR PWR SRC ERROR Invalid boost device configuration Cycle power on the power Invalid Boost Config
source
ERR PWR SRC ERROR Boost −15V power supply out of regu- Cycle power on the power Boost −15V Power Error
lation source
ERR PWR SRC ERROR Boost −24V power supply out of regu- Cycle power on the power Boost −24V Power Error
lation source
ERR PWR SRC ERROR Boost +15V power supply out of regu- Cycle power on the power Boost +15V Power Error
lation source
WRN VSNS LOS WARNING Lost volt sense lead feedback Inspect volt sense lead for Vsense Fallback Warning
break
ERR UNKNOWN ERROR An unknown error has occurred Update software Unknown Error

OM-273473 Page 48
9-4. Troubleshooting

Trouble Remedy
No weld output; completely inoperative Place line disconnect in On position (see Section 5-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11).
Check for proper input power connections (see Section 5-11).
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.
error displayed.

Erratic or improper weld output with no Use proper size and type of weld cable (see Section 5-2).
errors displayed.

Clean and tighten all weld connections.

Wire does not feed. Check supplementary protector CB1 and reset if necessary.
Check motor control cable connections.
Wire feeds erratically. Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.
Wire feeds as soon as power is supplied. Check gun trigger. See gun Owner’s Manual.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
Check voltage sense lead connection, clean and tighten if necessary.
Gas does not flow or does not stop flow- Check gas valve and flow meter.
ing; wire feeds.

Wire burns back to gun contact tip when Check to be sure that volt sense lead is connected to the work.
using electrode negative (straight
polarity) process.

OM-273473 Page 49
 SECTION 10 − ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For Auto-Contiuum 350 Model (Page 1 of 2)

OM-273473 Page 50
 273 905-B

OM-273473 Page 51
 Figure 10-2. Circuit Diagram For Auto-Continuum 350 Model (Page 2 of 2)
OM-273473 Page 52
 273 905-B

OM-273473 Page 53
 Figure 10-3. Circuit Diagram For Auto-Contiuum 500 Model (Page 1 of 2)

OM-273473 Page 54
 273 490-B

OM-273473 Page 55
 Figure 10-4. Circuit Diagram For Auto-Continuum 500 Model (Page 2 of 2)
OM-273473 Page 56
 273 490-B

OM-273473 Page 57
 SECTION 11 − PARTS LIST FOR 350 AND 500 MODELS

5 Figure 11-7
6
2
12 Figure 11-6
20

19

21
13
14 Figure 11-2
23
15 Figure 11-3
24
16 21
10
18 8 Figure 11-4

3
11

1 17
22

7
9

Figure 11-5

274585-B

Figure 11-1. Main Assembly

OM-273473 Page 58
 Item Dia. Part
No. Mkgs. No. Description Quantity
350 500
Figure 11-1. Main Assembly
Model Model
. . 1 . . . . . . . . . . . . . +265236 . . Base ,Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 269888 . . . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . 1 . . . . . 1
. . 2 . . . . . . . . . . . . . +265245 . . Panel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258431 . . . . Label, Warning General Precautionary (CE/Domestic) . . . . . . 1 . . . . . 1
. . 3 . . . . . . . . . . . . . +265246 . . Panel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258431 . . . . Label, Warning General Precautionary (CE/Domestic) . . . . . . 1 . . . . . 1
. . 4 . . . . . . . . . . . . . +265240 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258427 . . . . Label, Warning Falling Equipment . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 5 . . . . . . . . . . Figure 11-7 . . Rear Panel Assy, Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 274551 . . Bracket, Guard Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 7 . . . . . . . . . . . . . . 273400 . . Output Terminal Assy, (See Figure 11-5) . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 8 . . . . . . . . . . . Figure 11-4 . . Fan Panel Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 9 . . . . . . . . . . . Figure 11-5 . . Front Panel Assy, Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 10 . . . . . . . . . . . . . . 269472 . . Gasket, Sealing 17.000L x .250w x .063t . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . . . . . 273390 . . Assy, UI Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 12 . . . . . . . . . . . Figure 11-6 . . Penthouse Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 13 . . . . . . . . . . . . . . 270511 . . Insulator,.010 Thick X 4.500 X 8.000 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 14 . . . . . . . . . . . Figure 11-2 . . Windtunnel, Rh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 15 . . . . . . . . . . . Figure 11-3 . . Windtunnel, Lh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 16 . . . . PC1 . . . . 248915 . . Circuit Card Assy, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 17 . . . . PC4 . . . . 273420 . . Circuit Card Assy, Inverter - Arc Control Auto W/Prog . . . . . . . . 1 . . . . . 1
. . 18 . . . . PC14 . . . . 265925 . . Circuit Card Assy, Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258016 . . . . Fuse, Mintr Cer 1 Amp 1000V AC/DC . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 19 . . . . . . . . . . . . . . 271671 . . Circuit Card Assy, AIM Continuum w/Prog . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 20 . . . . HD2 . . . . 182918 . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . 1 . . . . . 1
. . 21 . . . . . . . . . . . . . . 266420 . . Plate, Lift Eye Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 22 . . . . . . . . . . . . . . 267407 . . Plate, Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 23 . . . . . . . . . . . . . . 273487 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 24 . . . . . . . . . . . . . . 269271 . . Insulator, Windtunnel/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 262913 . . Kit, Strain Relief 1.250 (Including) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 255675 . . . . Bushing, Strain Relief .865/1.26 Id x 1.250 Mtg Hole . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 263092 . . . . Nut, Conduit 1.250 Npsm Knurled . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 602177 . . . . Screw, Set 250−20 x .25 Knrlpt Sch stl Pln . . . . . . . . . . . . . . . . 1 . . . . . 1 . .
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-273473 Page 59
 . Hardware is common and
not available unless listed.
20
21
6
4 7
22
14

19 17 3
1
13
16

15

18

5 9 12

2 10

8 11 Ref. 269 780-C

Figure 11-2. Right-Hand Windtunnel w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity
Figure 11-2. Right-Hand Windtunnel 350 500
w/Components (Figure 11-1, Item 14) Model Model
. . 1 . . . . . . . . . . . . . . 265243 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 2 . . . . T1-T2 . . . 252442 . . Xfmr, Hf Litz (500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 2
. . 2 . . . . . T1 . . . . . 267776 . . Xfmr, Hf Litz (350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . . . . . . . . . . . . . . . . . . 263299 . . Heat Sink Assy, Output Diode (500)(Includes Items 3-7) . . . . . . 0 . . . . . 1
. . . . . . . . . . . . . . . . . . . 267924 . . Heat Sink Assy, Output Diode (350)(Includes Items 3-7) . . . . . . 1 . . . . . 0
. . 3 . . . . . . . . . . . . . . 213029 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 26.00in Lead . . . . . 1 . . . . . 1
. . 4 . . . . . . . . . . . . . . 199840 . . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 5 . . . . . . . . . . . . . . 272416 . . . . Heat Sink, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 233052 . . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 2
. . 7 . . . D1−D4 . . . 201531 . . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 8 . . . . . . . . . . . . . . 196355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4
. . 9 . . . . . . . . . . . . . . 025248 . . Stand-off, Insul .250-20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . 2 . . . . . 2
. . 10 . . . . . . . . . . . . . . 236727 . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . . . . . 179276 . . Bushing, Snap-in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . 2 . . . . . 2
. . 12 . . . . . . . . . . . . . . 253547 . . Bus Bar, Xfmr Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 13 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . 1 . . . . . 1
. . 14 . . . . . L5 . . . . . 273683 . . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 15 . . . . . . . . . . . . . . 223343 . . Clip, Wire Stdf .40-.50 Bndl .156hole .031-.078thk . . . . . . . . . . . 2 . . . . . 2
. . 16 . . . . . . . . . . . . . . 267438 . . Plate, Blank Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 17 . . . . . C5 . . . . . 265285 . . Capacitor,Polyp Met Film 30. Uf 550 Vdc . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . 18 . . . . . . . . . . . . . . 057360 . . Blank, Snap-In Nyl 1.375 Mtg Hole Black . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . 19 . . . . . . . . . . . . . . 267870 . . Plate, Mtg Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . 20 . . . . PC20 . . ♦271474 . . Circuit Card Assy, 115v Aux Power w/Prog & Potted . . . . . . . . . 1 . . . . . 1
. . 21 . . . . . . . . . . . . ♦271483 . . Bracket, Mtg Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 22 . . . . . . . . . . . . ♦271775 . . Inductor, Output Continuum Aux Module . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
♦OPTIONAL
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-273473 Page 60
 . Hardware is common and
not available unless listed. 7
10
1
2

12

11

5
4

269 781-A

Figure 11-3. Left-Hand Windtunnel w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity
Figure 11-3. Left-Hand Windtunnel 350 500
w/Components (Figure 11-1, Item 15) Model Model
. . 1 . . . . L1-L4 . . . . 252375 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 2 . . . . . . . . . . . . . . 265242 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 3 . . PC2-PC3 . . 248920 . . Circuit Card Assy, Capacitor (500) . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 2
. . 3 . . PC2-PC3 . . 265947 . . Circuit Card Assy, Capacitor (350) . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 0
. . 4 . . . . . . . . . . . . . . 259517 . . Kit, Transistor IGBT Module (Inverter) . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 5 . . . . . . . . . . . . . . 259515 . . Kit, Transistor IGBT Module (Boost) . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 6 . . . . . . . . . . . . . . 252449 . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.00in Lead . . . . . . . 1 . . . . . 1
. . 7 . . . . . . . . . . . . . . 173632 . . Thermistor, Ntc 30k Ohm @ 25 Deg C 12.00in Lead . . . . . . . 1 . . . . . 1
. . 8 . . . . . . . . . . . . . . 262497 . . Stand-off Support, PC Card .156 Dia W/P&L 1.125 . . . . . . . . . . 1 . . . . . 1
. . 9 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . 4 . . . . . 6
. . 10 . . . . . . . . . . . . . . 266939 . . Heat Sink, Igbt Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . . . . . 266940 . . Heat Sink, Igbt Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 12 . . . . . . . . . . . . . . 184260 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 047838 . . Blank, Snap-In Nyl 1.000 Mtg Hole Black . . . . . . . . . . . . . . . . . . . 2 . . . . . 0
. . . . . . . . . . . . . . . . . . . 267386 . . Plate, Input Inductor Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-273473 Page 61
 . Hardware is common and
not available unless listed.

4 5

1 3

269 782-B

Figure 11-4. Fan Panel Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 11-4. Fan Panel Assembly (Figure 11-1, Item 8)

. . 1 . . . . . . . . . . . . . . 265241 . . Panel, Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . FM1-FM2 . . 213072 . . Fan, Muffin 115v 60hz 3400 Rpm 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 2
. . 3 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 3
. . 5 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . . 2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-273473 Page 62
Notes

OM-273473 Page 63
 . Hardware is common and
not available unless listed.

5
4
3
2

24

19
7

9 17
15
14 20

16

23 22
8 21

13
10 12
11
18

274588A

Figure 11-5. Front Panel Assembly

OM-273473 Page 64
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-5. Front Panel Assembly (Figure 11-1, Items 7, 9)

. . 1 . . . . . . . . . . . . . . 252825 . . Bezel, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 253548 . . Panel, Top Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 256859 . . Circuit Card Assy, Led . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 261870 . . Cover, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 252445 . . Switch, Rotary On/Off 3PH 20Amp 600V 2 Layer . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 265467 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 7 . . . . . . . . . . . . . . 252821 . . Enclosure, Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 8 . . . . . . . . . . . . . . 262325 . . Panel, Front Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 265239 . . Panel, Output Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 269799 . . . Terminal Pwr Assy, Output Tabbed (Includes) . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 260223 . . . . Terminal, Pwr Output Tabbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 186228 . . . . O-ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 250037 . . . . Insulator, Bulkhead Front .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 185718 . . . . O-ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 250039 . . . . Insulator, Bulkhead Rear .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 185714 . . . . Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 185717 . . . . Nut, M20-1.5 1.00hex .19h Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 269800 . . . Terminal Pwr Assy, Output Front Bolted Rear (Includes) . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . . . 252830 . . . . Terminal, Pwr Output Front Bolted Rear Int Thread . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 186228 . . . . O-ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 250037 . . . . Insulator, Bulkhead Front .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 185718 . . . . O-ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 250039 . . . . Insulator, Bulkhead Rear .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 185714 . . . . Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 185717 . . . . Nut, M20-1.5 1.00hex .19h Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . . . 229333 . . Screw, M10-1.5x 20 Hex Hd-pln 8.8 Pld Sems . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 256961 . . Lead List, Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . C4 . . . . . 138695 . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . VR2 . . . . 269178 . . . Varistor, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 23 . . . . . . . . . . . . . . 057359 . . Blank, Snap-in Nyl .375 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . 273488 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 605603 . . . Tubing, Gl Acryl 1.000−1.036 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate Continuum (Order By Model & Serial No.) . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-273473 Page 65
 . Hardware is common and 10 2
not available unless listed.

11 8

3
6
4 7

1
5

269784-C

Figure 11-6. Penthouse Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 11-6. Penthouse Assembly (Figure 11-1, Item 12)

. . 1 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 7

. . 2 . . . . . W1 . . . . . 180270 . . Contactor, Def Prp 40a 3p 24vac Coil W/Boxlug . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 275142 . . Bracket, Mtg Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 145743 . . Lug, Univ W/Scr 600V 2-14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . +265238 . . Panel, Upper Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 155436 . . . . Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 136076 . . Resistor, Ww Fxd 30 W 200 Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . +265261 . . Lift Eye, Formed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 266393 . . . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 266232 . . Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 256975 . . Seal, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . PC19 . . . . 273411 . . Assy, Communication Package Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 262090 . . Feeder Power Board Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PC13 . . . . 252512 . . . . Circuit Card Assy, Control Feeder Power Pri . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 258016 . . . . . . Fuse, Mintr Cer 1 Amp 1000V AC/DC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 262089 . . . . Bracket, Feeder Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . ♦276453 . . . . Circuit Card Assy, Devicenet Interface Continuum . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-273473 Page 66
 9 8
14 . Hardware is common and
not available unless listed.
6
1 5

10 4

7 11

15

16 12

17 2

13

Ref. 274590C

Figure 11-7. Rear Panel Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-7. Rear Panel Assembly (Figure 11-1, Item 5)

. . 1 . . . . . . . . . . . . . +273395 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 258429 . . . . Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 274436 . . . . Label, E−Stop−Peripherals Auto−Continuum . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate Rear (Order By Model And Serial Number) . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 257290 . . Panel, Rear Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 263536 . . Rail, Din 35mm X 7.5mm X 1.969in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . PC16 . . . . 261838 . . Circuit Card Assy, Power Source 10 Pin Filter . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . CB1 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 269208 . . Plugs, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 260822 . . Antenna,Rf Monopole 2.4ghz Screw Mount . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 275563 . . Cable Assy, Rj45 Male/M12 Female .4m Lg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 275313 . . Panel, Rear Enet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 269416 . . . . Label,Ethernet/Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 271543 . . Cable Assy,Rf Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . RC15 . . ♦214918 . . Rcpt, Str Dx Grd 2p3w 20a 125v 5−20r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . ♦257289 . . Panel, Rear Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . ♦252139 . . Cover, Receptacle Duplex GFCI Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . CB2 . . ♦093995 . . Supplementary Pro, Man Reset 1p 15a 250Vac . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 000527 . . Blank, Snap−In Nyl .875 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . ♦224012 . . Plate, Rotation Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . ♦198956 . . Receptacle, Devicenet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-273473 Page 67
Notes
Notes
Notes
 Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
for your local EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the
reliable response you * Roughneck Guns
troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure. * Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. below in the event of such a failure within the warranty time periods. 1. Consumable components; such as contact tips,
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support to the original end-user purchaser, and not to exceed twelve months station table tops and welding curtains, or parts that
Need fast answers to the after the equipment is shipped to a North American distributor or fail due to normal wear. (Exception: brushes and
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is * Original Main Power Rectifiers Only to Include SCRs, covered by the manufacturer’s warranty, if any.
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. 2. 3 Years — Parts and Labor Miller, or equipment that has been improperly installed,
* Auto-Darkening Helmet Lenses (Except Classic improperly operated or misused based upon industry
Series) (No Labor) standards, or equipment which has not had reasonable
* Engine Driven Welder/Generators and necessary maintenance, or equipment which has
(NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
3. 2 Years — Parts and Labor replacement; or, where authorized in writing by Miller in appropriate
* Auto-Darkening Helmet Lenses − Classic Series Only cases, (3) the reasonable cost of repair or replacement at an
(No Labor) authorized Miller service station; or (4) payment of or credit for the
* Fume Extractors − Capture 5, Filtair 400 and Industrial purchase price (less reasonable depreciation based upon actual
Collector Series 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
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
* CoolBelt and CoolBand Blower Unit (No Labor) reimbursement for transportation costs of any kind will be allowed.
* Desiccant Air Dryer System TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* External Monitoring Equipment and Sensors PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Field Options REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
(NOTE: Field options are covered for the remaining DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is
LEGAL THEORY.
greater.)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* LiveArc Welding Performance Management System
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Load Banks MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns) Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
* Water Coolant Systems
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2016-01
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
[Link]
Welding Process Handbooks
To locate a Distributor or Service Agency visit
[Link] or call 1-800-4-A-Miller

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01