Dimension NT 450

Processes

Description

Multiprocess Welding

Arc Welding Power Source

OM-2252 218 084J200605

Visit our website at

www.MillerWelds.com

File: Multiprocess Welding

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you dont have time to doit any other way.

Thats why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldnt afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,theres a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 4/05

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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symboles utiliss 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage larc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7 . . . . . . 2-4. Proposition californienne 65 Avertissements 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de scurit 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Information EMF 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. General Precautionary Label 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Nameplate Safety Symbols 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Input Connection Label 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Electric Shock And Airflow Label 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Specifications 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Duty Cycle And Overheating 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Volt-Ampere Curves 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Selecting A Location 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Dimensions And Weights 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Tipping 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. 115 VAC Receptacle And Circuit Breakers 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Weld Output Terminals And Selecting Cable Sizes 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Connecting Weld Output Cables 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Remote 14 Receptacle Information 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Connecting Remote Control 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Electrical Service Guide 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13. Placing Jumper Links 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14. Connecting Input Power 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Controls 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Meter Functions For CC/CV Models 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Lift-Arc TIG Procedure For CC/CV Models 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE & TROUBLESHOOTING 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Fuse F1 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Voltmeter/Ammeter Help Displays 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Troubleshooting 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 PARTS LIST 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIESWARRANTY

Notes

OM-2252 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05

Warning: Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Marks a special safety message.

Means Note; not safety related.

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

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats

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

Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

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

unit. Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic 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 welderis recommended. And, do not work alone!

Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

When making input connections, attach proper grounding conduc-tor first double-check connections.

Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

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

with a separate cable. Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine. Do not touch electrode holders connected to two welding ma-

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

Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent

contact with any metal object. Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-typewelding power sources after removal of inputpower. Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

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

arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

OM-2252 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

Wear an approved welding helmet fitted with a proper shade of fil-ter lenses to protect your face and eyes when welding or watching(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under yourhelmet.

Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-rial (leather, heavy cotton, or wool) and foot protection.

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

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

torch. To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away. Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is inuse or connected for use.

Use the right equipment, correct procedures, and sufficient num-ber of persons to lift and move cylinders.

Read and follow instructions on compressed gas cylinders,associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.

OM-2252 Page 3

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

FIRE OR EXPLOSION hazard.

Do not install or place unit on, over, or nearcombustible surfaces.

Do not install unit near flammables.

Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to lift andsupport unit.

If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

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

starting to weld again. Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handlingboards or parts.

Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can cause injury.

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

rolls.

WELDING WIRE can cause injury.

Do not press gun trigger until instructed to doso.

Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury.

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

closed and securely in place. Have only qualified persons remove doors,

panels, covers, or guards for maintenance asnecessary.

Reinstall doors, panels, covers, or guardswhen maintenance is finished and before re-connecting input power.

READ INSTRUCTIONS.

Read Owners Manual before using or servic-ing unit.

Use only genuine Miller/Hobart replacementparts.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

Have only qualified persons familiar withelectronic equipment perform this installation.

The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

If notified by the FCC about interference, stop using theequipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

Be sure all equipment in the welding area iselectromagnetically compatible.

To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-tronic equipment.

Be sure this welding machine is installed and groundedaccording to this manual.

If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases whichcontain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

For Gasoline Engines: Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductiveharm.

For Diesel Engines: Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, andother reproductive harm.

OM-2252 Page 4

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1 from Global Engineering Documents (phone:1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA022699101 (phone: 6177703000, website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web-site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:8004636727 or in Toronto 4167474044, website: www.csain-ternational.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, from American National Standards Institute, 11West 42nd Street, New York, NY 100368002 (phone: 2126424900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:6177703000, website: www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (thereare 10 Regional Officesphone for Region 5, Chicago, is3123532220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

About Pacemakers:Pacemaker wearers consult your doctor before welding or going nearwelding operations. If cleared by your doctor, then following the aboveprocedures is recommended.

OM-2252 Page 5

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATIONsom _3/05

Avertissement : se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

Symbole graphique davertissement ! Attention ! Cette pro-cdure comporte des risques possibles ! Les dangers ven-tuels sont reprsents par les symboles graphiques joints.

Indique un message de scurit particulier

Signifie NOTE ; nest pas relatif la scurit.

Ce groupe de symboles signifie Avertissement ! Attention ! RisquesdLECTROCUTION, ORGANES MOBILES et PARTIESCHAUDES. Consulter les symboles et les instructions affrentes ci-dessous concernant les mesures prendre pour supprimerles dangers.

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce manuelpour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructions enmatire de scurit indiques ci-dessous ne constituent quunsommaire des instructions de scurit plus compltes fourniesdans les normes de scurit numres dans la Section 2-5. Lire etobserver toutes les normes de scurit.

Seul un personnel qualifi est autoris installer, faire fonction-ner, entretenir et rparer cet appareil.

Pendant le fonctionnement, maintenir distance toutes les per-sonnes, notamment les enfants de lappareil.

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr la

sortie. Le circuit dalimentation et les circuits internes de la machinesont galement sous tension lorsque lalimentation est sur Marche.Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalliques en contactavec le fil sont sous tension lectrique. Un quipement install ou mis la terre de manire incorrecte ou impropre constitue un danger.

Ne pas toucher aux pices lectriques sous tension. Porter des gants isolants et des vtements de protection secs et sans

trous. Sisoler de la pice couper et du sol en utilisant des housses ou des

tapis assez grands afin dviter tout contact physique avec la pice couper ou le sol.

Ne pas se servir de source lectrique courant lectrique dans les zo-nes humides, dans les endroits confins ou l o on risque de tomber.

Se servir dune source lectrique courant lectrique UNIQUEMENT sile procd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savre n-cessaire, se servir de la fonction de tlcommande si lappareil en estquip.

Dautres consignes de scurit sont ncessaires dans les conditionssuivantes : risques lectriques dans un environnement humide ou si lonporte des vtements mouills ; sur des structures mtalliques telles quesols, grilles ou chafaudages ; en position coince comme assise, ge-noux ou couche ; ou sil y a un risque lev de contact invitable ouaccidentel avec la pice souder ou le sol. Dans ces conditions, utiliserles quipements suivants, dans lordre indiqu : 1) un poste souder DC tension constante ( fil), 2) un poste souder DC manuel (lectrode)ou 3) un poste souder AC tension vide rduite. Dans la plupart dessituations, lutilisation dun poste souder DC fil tension constanteest recommande. En outre, ne pas travailler seul !

Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes descurit).

Installer le poste correctement et le mettre la terre convenablementselon les consignes du manuel de loprateur et les normes nationales,provinciales et locales.

Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurerque le fil de terre du cordon dalimentation est bien raccord la bornede terre du sectionneur ou que la fiche du cordon est raccorde uneprise correctement mise la terre.

En effectuant les raccordements dentre, fixer dabord le conducteurde mise la terre appropri et contre-vrifier les connexions.

Vrifier frquemment le cordon dalimentation afin de sassurer quilnest pas altr ou nu, le remplacer immdiatement sil lest. Un fil nupeut entraner la mort.

Lquipement doit tre hors tension lorsquil nest pas utilis. Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante

ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct. Ne pas toucher llectrode quand on est en contact avec la pice, la terre

ou une lectrode provenant dune autre machine. Ne pas toucher des porte lectrodes connects deux machines en

mme temps cause de la prsence dune tension vide double. Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-

champ les pices endommages. Entretenir lappareil conformment ce manuel.

Porter un harnais de scurit si lon doit travailler au-dessus du sol. Sassurer que tous les panneaux et couvercles sont correctement en

place. Fixer le cble de retour de faon obtenir un bon contact mtal-mtal

avec la pice souder ou la table de travail, le plus prs possible de lasoudure.

Isoler la pince de masse quand pas mis la pice pour viter le contactavec tout objet mtallique.

Ne pas raccorder plus dune lectrode ou plus dun cble de masse une mme borne de sortie de soudage.

Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur quand on a couplalimentation. Arrter les convertisseurs, dbrancher le courant lectrique et

dcharger les condensateurs dalimentation selon les instructions indi-ques dans la partie Entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereuse pour la sant.

LES FUMES ET LES GAZ peuventtre dangereux.

Ne pas mettre sa tte au-dessus des vapeurs. Ne pas respirer ces va-peurs.

lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau delarc pour lvacuation des fumes et des gaz de soudage.

Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approu-v.

Lire et comprendre les spcifications de scurit des matriaux (MSDS) etles instructions du fabricant concernant les mtaux, les consommables, lesrevtements, les nettoyants et les dgraisseurs.

Travailler dans un espace ferm seulement sil est bien ventil ou enportant un respirateur alimentation dair. Demander toujours un sur-veillant dment form de se tenir proximit. Des fumes et des gaz desoudage peuvent dplacer lair et abaisser le niveau doxygne provo-quant des blessures ou des accidents mortels. Sassurer que lair derespiration ne prsente aucun danger.

Ne pas souder dans des endroits situs proximit doprations de d-graissage, de nettoyage ou de pulvrisation. La chaleur et les rayons delarc peuvent ragir en prsence de vapeurs et former des gaz haute-ment toxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que lacier gal-vanis, plaqu en plomb ou au cadmium moins que le revtement naitt enlev dans la zone de soudure, que lendroit soit bien ventil et enportant un respirateur alimentation dair. Les revtements et tous lesmtaux renfermant ces lments peuvent dgager des fumes toxi-ques en cas de soudage.

OM-2252 Page 6

Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provo-quer des brlures dans les yeux et sur la peau.

Des tincelles sont projetes pendant le soudage.

LES RAYONS DARC peuvent entra-ner des brlures aux yeux et la peau.

Porter un casque de soudage approuv muni de verres filtrants ap-propri pour protger visage et yeux pendant le soudage (voir ANSIZ49.1 et Z87.1 numr dans les normes de scurit).

Porter des lunettes de scurit avec crans latraux mme sous vo-tre casque.

Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissements etles tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

Porter des vtements confectionns avec des matires rsistanteset ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuventtre projetes de larc de soudure. La projection

dtincelles, des pices chaudes et des quipements chauds peuventprovoquer des incendies et des brlures. Le contact accidentel dellectrode avec des objets mtalliques peut provoquer des tincelles,une explosion, une surchauffe ou un incendie. Avant de commencerle soudage, vrifier et sassurer que lendroit ne prsente pas dedanger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit, les recouvrir soi-gneusement avec des protections homologues.

Ne pas souder dans un endroit o des tincelles peuvent tomber surdes substances inflammables.

Se protger, ainsi que toute autre personne travaillant sur les lieux,contre les tincelles et le mtal chaud.

Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

Afin dliminer tout risque de feu, tre vigilant et garder toujours unextincteur la porte de main.

Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

Ne pas effectuer le soudage sur des conteneurs ferms tels que desrservoirs, tambours, ou conduites, moins quils naient t prpa-rs correctement conformment AWS F4.1 (voir les normes descurit).

Brancher le cble de masse sur la pice le plus prs possible de lazone de soudage pour viter le transport du courant sur une longuedistance par des chemins inconnus ventuels en provoquant desrisques dlectrocution, dtincelles et dincendie.

Ne pas utiliser le poste de soudage pour dgeler des conduitesgeles.

En cas de non-utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

Porter des vtements de protection exempts dhuile tels que desgants en cuir, une veste rsistante, des pantalons sans revers, desbottes et un casque.

Avant de souder, retirer toute substance combustible de ses pochestelles quun allumeur au butane ou des allumettes.

Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51Bpour travaux de soudage et prvoir un dtecteur dincendie et un ex-tincteur proximit.

DES PARTICULES VOLANTESpeuvent blesser les yeux. Le soudage, lcaillement, le passage de la

pice la brosse en fil de fer, et le meulagegnrent des tincelles et des particulesmtalliques volantes. Pendant la priode derefroidissement des soudures, elles risquentde projeter du laitier.

Porter des lunettes de scurit avec crans latraux ou un cranfacial.

LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort. Fermer lalimentation du gaz protecteur en cas

de non-utilisation. Veiller toujours bien arer les espaces confi-

ns ou se servir dun respirateur dadductiondair homologu.

DES PICES CHAUDES peuventprovoquer des brlures graves. Ne pas toucher des parties chaudes mains

nues. Prvoir une priode de refroidissement avant

dutiliser le pistolet ou la torche. Ne pas toucher aux pices chaudes, utiliser les outils recom-

mands et porter des gants de soudage et des vtements paispour viter les brlures.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques. Porteurs de stimulateur cardiaque, rester

distance. Les porteurs dun stimulateur cardiaque doi-

vent dabord consulter leur mdecin avant desapprocher des oprations de soudage larc,de gougeage ou de soudage par points.

LE BRUIT peut endommager loue.Le bruit des processus et des quipements peutaffecter loue.

Porter des protections approuves pour lesoreilles si le niveau sonore est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-ge, elle peut exploser. Du fait que les bouteilles degaz font normalement partie du procd de soudage, les manipuler avec prcaution.

Protger les bouteilles de gaz comprim dune chaleur excessi-ve, des chocs mcaniques, des dommages physiques, du lai-tier, des flammes ouvertes, des tincelles et des arcs.

Placer les bouteilles debout en les fixant dans un support sta-tionnaire ou dans un porte-bouteilles pour les empcher de tom-ber ou de se renverser.

Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

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

une bouteille. Ne jamais souder une bouteille pressurise risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifi-que ; les maintenir ainsi que les lments associs en bon tat.

Dtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

Le couvercle du dtendeur doit toujours tre en place, sauf lors-que la bouteille est utilise ou quelle est relie pour usage ult-rieur.

Utiliser les quipements corrects, les bonnes procdures et suf-fisamment de personnes pour soulever et dplacer les bouteil-les.

Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scuri-t.

LES BOUTEILLES peuvent explosersi elles sont endommages.

OM-2252 Page 7

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLO-SION. Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables. Ne pas installer lappareil proximit de

produits inflammables. Ne pas surcharger linstallation lectrique sassurer que

lalimentation est correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LAPPAREIL peutblesser. Utiliser lanneau de levage uniquement pour

soulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

LEMPLOI EXCESSIF peut SUR-CHAUFFER LQUIPEMENT. Prvoir une priode de refroidissement ;

respecter le cycle opratoire nominal. Rduire le courant ou le facteur de marche

avant de poursuivre le soudage. Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATIQUESpeuvent endommager les circuitsimprims. tablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistati-

ques pour stocker, dplacer ou expdier descartes PC.

DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures. Ne pas appuyer sur la gchette avant den

avoir reu linstruction. Ne pas diriger le pistolet vers soi, dautres

personnes ou toute pice mcanique en enga-geant le fil de soudage.

DES ORGANES MOBILES peuventprovoquer des blessures. Sabstenir de toucher des organes mobiles tels

que des ventilateurs. Maintenir ferms et verrouills les portes,

panneaux, recouvrements et dispositifs deprotection.

Seules des personnes qualifies sont autorises enlever lesportes, panneaux, recouvrements ou dispositifs de protectionpour lentretien.

Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS. Lire le manuel dutilisation avant dutiliser ou

dintervenir sur lappareil. Utiliser uniquement des pices de rechange

Miller/Hobart.

LE RAYONNEMENT HAUTEFRQUENCE (HF) risque de provoquerdes interfrences. Le rayonnement haute frquence (HF) peut

provoquer des interfrences avec les quipe-ments de radio-navigation et de communica-tion, les services de scurit et les ordinateurs.

Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstal-lation.

Lutilisateur est tenu de faire corriger rapidement par un lectri-cien qualifi les interfrences rsultant de linstallation.

Si le FCC signale des interfrences, arrter immdiatementlappareil.

Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs unedistance correcte et utiliser une terre et un blindage pour rduireles interfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences. Lnergie lectromagntique peut gner le

fonctionnement dappareils lectroniquescomme des ordinateurs et des robots.

Veiller ce que tout lquipement de la zone desoudage soit compatible lectromagntiquement.

Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation decbles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiques dontltat de Californie reconnat quils provoquent des malformationscongnitales et, dans certains cas, des cancers. (Code de sant etde scurit de Californie, chapitre 25249.5 et suivants)

Les batteries, les bornes et autres accessoires contiennent duplomb et des composs base de plomb, produits chimiquesdont ltat de Californie reconnat quils provoquent des can-cers et des malformations congnitales ou autres problmes deprocration. Se laver les mains aprs manipulation.

Pour les moteurs essence : Les gaz dchappement des moteurs contiennent des produits

chimiques dont ltat de Californie reconnat quils provoquentdes cancers et des malformations congnitales ou autres pro-blmes de procration.

Pour les moteurs diesel : Les gaz dchappement des moteurs diesel et certains de leurs

composants sont reconnus par ltat de Californie commeprovoquant des cancers et des malformations congnitales ou au-tres problmes de procration.

OM-2252 Page 8

2-5. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, site In-ternet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society Standard AWSF4.1 de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire ProtectionAssociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite1004, Arlington, VA 22202-4102 (tlphone : 703-412-0900, site Internet: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, deCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (tlphone :800-463-6727 ou Toronto 416-747-4044, site Internet :www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, de American National Standards Institute, 11 West42nd Street, New York, NY 10036-8002 (tlphone : 212-642-4900, siteInternet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, de National Fire Protection Association, P.O.Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (tlphone :617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Industry,Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, andPart 1926, Subpart J, de U.S. Government Printing Office, Superinten-dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10bureaux rgionauxle tlphone de la rgion 5, Chicago, est312-353-2220, site Internet : www.osha.gov).

2-6. Information EMF

Considrations sur le soudage et les effets de basse frquence et deschamps magntiques et lectriques.

Le courant de soudage, pendant son passage dans les cbles de souda-ge, causera des champs lectromagntiques. Il y a eu et il y a encore uncertain souci propos de tels champs. Cependant, aprs avoir examinplus de 500 tudes qui ont t faites pendant une priode de recherchede 17 ans, un comit spcial ruban bleu du National Research Council aconclu : Laccumulation de preuves, suivant le jugement du comit, napas dmontr que lexposition aux champs magntiques et champs lec-triques haute frquence reprsente un risque la sant humaine .Toutefois, des tudes sont toujours en cours et les preuves continuent tre examines. En attendant que les conclusions finales de la recherchesoient tablies, il vous serait souhaitable de rduire votre exposition auxchamps lectromagntiques pendant le soudage ou le coupage.

Pour rduire les champs magntiques sur le poste de travail, appliquerles procdures suivantes :

1. Maintenir les cbles ensemble en les tordant ou en les enveloppant.

2. Disposer les cbles dun ct et distance de loprateur.

3. Ne pas courber pas et ne pas entourer pas les cbles autour devotre corps.

4. Garder le poste de soudage et les cbles le plus loin possible devous.

5. Connecter la pince sur la pice aussi prs que possible de la sou-dure.

En ce qui concerne les stimulateurs cardiaquesLes porteurs de stimulateur cardiaque doivent consulter leur mdecinavant de souder ou dapprocher des oprations de soudage. Si le mde-cin approuve, il est recommand de suivre les procdures prcdentes.

OM-2252 Page 9

SECTION 3 DEFINITIONS3-1. General Precautionary Label

Warning! Watch Out! There arepossible hazards as shown by thesymbols.

3-2. Nameplate Safety Symbols1 Warning! Watch Out! There

are possible hazards asshown by the symbols.

2 Electric shock from weldingelectrode or wiring can kill.

3 Sparks from arcing electrodecan cause explosion or fire disconnect cable for processnot in use.

4 Read Owners Manual forconnection procedures.

5 Electric shock from wiring cankill.

6 Disconnect input powerbefore working on unit ormaking terminal stripconnections.

Nameplate D-179 389

1

2 3 45 6

1

OM-2252 Page 10

3-3. Input Connection Label1 Warning! Watch Out! There

are possible hazards asshown by the symbols.

1

3-4. Electric Shock And Airflow Label1 Warning! Watch Out! There

are possible hazards asshown by the symbols.

1

OM-2252 Page 11

SECTION 4 INSTALLATION

4-1. Specifications

ModelRated Welding

OutputAmperage/Voltage

Range Max OCVDC

Amperes Input at Rated LoadOutput 60 Hz, Three-PhaseModel Output Range Max OCVDC

230 V 460 V 575 V KVA KW

450 Amp450 A @ 38 VoltsDC 100% Duty

5 500A In CCMode

80 VDC In CC Mode 57 29 23 22.6 21.0

450 Amp DC, 100% DutyCycle 10 38V In CV

Mode80 VDC InCV Mode

*2.18 *1.04 *0.84 *0.87 *0.29

*While idling

4-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.

Exceeding duty cycle candamage unit and voidwarranty.

100% Duty Cycle

Overheating0

15

A/V

ORReduce Duty CycleMinutes

duty1 4/95 / 210 976-B

Continuous Welding

OM-2252 Page 12

4-3. Volt-Ampere CurvesVolt-ampere curves show mini-mum and maximum voltage andamperage output capabilities ofunit. Curves of other settings fall be-tween curves shown.

va_curve1 4/95 212 111-A / 212 112-A

A. CC Mode

B. CV Mode

0

10

20

30

40

50

60

70

80

90

0 100 200 300 400 500 600 700 800

DC Current

DC

Vo

ltag

e

0

10

20

30

40

50

60

70

80

90

0 100 200 300 400 500 600

DC Current

DC

Vo

ltag

e

OM-2252 Page 13

4-4. Selecting A Location1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks tomove unit.

If using lifting forks, extend forksbeyond opposite side of unit.

3 Rating Label

Use rating label to determine inputpower needs.

4 Line Disconnect Device

Locate unit near correct input pow-er supply.

Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

4

18 in(460 mm)

18 in(460 mm)

OR

1

2

Movement

Location

3

OM-2252 Page 14

4-5. Dimensions And Weights

Dimensions

A 30 in (762 mm) including lift eye

B 23 in (585 mm)

C 38 in (966 mm) including strain relief

D 35 in (889 mm)

E 1-1/4 in (32 mm)

F 21-1/8 in (537 mm)

G 1-1/8 in (29 mm)

H 7/16 in (11 mm) Dia

Weight

376 lb (171 kg)

800 453-A / 801 530

D

E

F

G H

4 Holes

A

BC

Front

OM-2252 Page 15

4-6. Tipping Be careful when placing or

moving unit over unevensurfaces.

4-7. 115 VAC Receptacle And Circuit Breakers

Ref. 800 166-D

Turn Off power beforeconnecting to receptacle.

1 115 V 15 A AC ReceptacleRC15

Power is shared between RC15and Remote 14 receptacle RC14(see Section 4-11).

2 Circuit Breaker CB1

3 Circuit Breaker CB2

CB1 protects the 115 volts ac por-tion of RC14 and RC15 fromoverload.

CB2 protects the 24 volts ac portionof RC14 from overload.

Press button to reset breaker.

1

3

2

OM-2252 Page 16

4-8. Weld Output Terminals And Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

Turn Off power beforeconnecting to weld output

terminals.

WeldingAmperes

10 60%DutyCycle

60 100%Duty Cycle 10 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

NegativePositive Terminal

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0Terminal

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0

*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. Contact your distributor forthe mm2 equivalent weld cable sizes. S-0007-E

4-9. Connecting Weld Output Cables

803 778-B

Turn off power before connecting toweld output terminals.

Failure to properly connect weldcables may cause excessive heatand start a fire, or damage your ma-chine.

1 Weld Output Terminal

2 Supplied Weld Output Terminal Nut

3 Weld Cable Terminal

4 Copper Bar

Remove supplied nut from weld output ter-

minal. Slide weld cable terminal onto weldoutput terminal and secure with nut so thatweld cable terminal is tight against copperbar. Do not place anything between weldcable terminal and copper bar. Makesure that the surfaces of the weld cableterminal and copper bar are clean.

Tools Needed:

3/4 in (19 mm)

4

2

3

Do not placeanything between

Correct Installation Incorrect Installation

1

weld cable terminaland copper bar.

OM-2252 Page 17

4-10. Remote 14 Receptacle Information

Socket* Socket Information

24 VOLTS AC A 24 volts ac. Protected by circuit breaker CB2.

B Contact closure to A completes 24 volts ac contactor control circuit.

115 VOLTS AC I 115 volts ac. Protected by circuit breaker CB1.

J Contact closure to I completes 115 volts ac contactor control circuit.

C Output to remote control; +10 volts dc in MIG mode.

REMOTEOUTPUT

D Remote control circuit common.

OUTPUTCONTROL E 0 to +10 volts dc input command signal from remote control.

M CC/CV select.

A/VAMPERAGE

F Current feedback; +1 volt dc per 100 amperes.

AMPERAGEVOLTAGE H Voltage feedback; +1 volt dc per 10 arc volts.

GNDG Circuit common for 24 and 115 volts ac circuits.

GNDK Chassis common.

*The remaining sockets are not used.

4-11. Connecting Remote Control

Ref. 800 166-D / Ref. S-0004-A / S-0750

Turn off power before con-necting to Remote 14 recep-tacle.

1 Remote 14 Receptacle RC14

Connect remote control to RC14.

A JB K I

C L N H

D M GE F

1

OR OR

OM-2252 Page 18

4-12. Electrical Service Guide

60 Hertz Models

Input Voltage 230 460 575

Input Amperes At Rated Output 57 29 23

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay 2 70 35 25

Normal Operating 3 90 40 35

Min Input Conductor Size In AWG 4 6 10 10

Max Recommended Input Conductor Length In Feet (Meters) 145 (44) 243 (74) 380 (116)

Min Grounding Conductor Size In AWG 4 8 10 10

Reference: 2005 National Electrical Code (NEC)

1 Consult factory for circuit breaker applications.2 Time-Delay fuses are UL class RK5 .3 Normal Operating (general purpose no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and

above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

4-13. Placing Jumper Links

Ref. 800 103-A

Disconnect and lockout/tag-out input power beforeinstalling or moving jumperlinks.

Check input voltage available atsite.

1 Jumper Link Label

Check label.

2 Jumper Links

Move jumper links to match inputvoltage.

Close access door, or go on toSection 4-14.

Tools Needed:

2

1

Do not overtightenjumper link nuts.

230 VOLTS

Ref. S-174 973-A

575 VOLTS460 VOLTS

3/8 in

3/8 in

OM-2252 Page 19

4-14. Connecting Input Power

1/2 in

3/8 in

Tools Needed:

800 103-C / Ref. 801 116-A

Installation must meet all Nationaland Local Codes have only quali-fied persons make this installation.

Disconnect and lockout/tagout in-put power before connecting inputconductors from unit.

Make input power connections tothe welding power source first.

Always connect green or green/yellow conductor to supplygrounding terminal first, and neverto a line terminal.

See rating label on unit and check inputvoltage available at site.

1 Input Power Conductors (CustomerSupplied Cord)

Select size and length of conductors usingSection 4-12. Conductors must complywith national, state, and local electricalcodes. If applicable, use lugs of properamperage capacity and correct hole size.

Welding Power Source Input PowerConnections

2 Strain Relief

Route conductors (cord) through strain re-lief and tighten screws.

3 Machine Grounding Terminal

4 Green Or Green/Yellow GroundingConductor

5 Reed Switch (Ground CurrentSensor) (Optional)

Connect green or green/yellow groundingconductor to welding power sourcegrounding terminal first. If unit is equippedwith optional ground current sensor, routegrounding conductor through reed switchtwo times and connect to grounding termi-nal.

6 Welding Power Source LineTerminals

7 Input Conductors L1 (U), L2 (V) AndL3 (W)

Connect input conductors L1 (U), L2 (V)and L3 (W) to welding power source lineterminals.

Close and secure access door on weldingpower source.

Disconnect Device Input Power Con-nections

8 Disconnect Device (switch shown inOFF position)

9 Disconnect Device (Supply)Grounding Terminal

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

10 Disconnect Device Line Terminals

Connect input conductors L1 (U), L2 (V)And L3 (W) to disconnect device lineterminals.

11 Overcurrent Protection

Select type and size of overcurrent protec-tion using Section 4-12 (fused disconnectswitch shown).

Close and secure door on line disconnectdevice. Remove lockout/tagout device,and place switch in the On position.

IMPORTANT

GND/

3

PE Earth Ground

Input Contactor

L1 (U)

L2 (V)

L3 (W)

= GND/PE Earth Ground

8

5

4

2

11

6

3

7

4

9

4

10

1

=

7

OM-2252 Page 20

SECTION 5 OPERATION5-1. Controls

229 448-A1

2 3 6

74

5

1 Power Switch

This unit is equipped with a fan motor thatis thermostatically controlled and onlyruns when cooling is needed.

2 Voltmeter (see Section 5-2)

3 Ammeter (see Section 5-2)

4 Mode Switch

Use Mode switch to determine both processand output On/Off control. Orange areashighlight contactor on positions.

5 Panel/Remote Control Switch

For front panel control, place switch in Panelposition and use the V/A Adjust control to setamperage or voltage, depending on Modeswitch selection.

For remote control, make connections to Re-mote 14 receptacle (see Section 4-11), andplace switch in Remote position. In TIGmodes, output available through the remotecontrol is a percent of the V/A Adjust controlsetting. Value selected on V/A Adjust control

is maximum output available through the re-mote control. In the MIG, CC, and V-Sensefeeder modes, a remote control provides fullrange of unit output regardless of V/A Adjustcontrol setting. A remote control is not func-tional in Air-Carbon Arc or Stick modes. Ifconnection to Remote 14 receptacle is re-moved and Panel/Remote control switch re-mains in Remote position, output is controlledwith the V/A Adjust control.

6 V/A (Voltage/Amperage) Adjust Control

With Mode switch in any Stick or TIG position,use control to adjust amperage from 5 to 500amps. With Mode switch in a V-Sense Feederor MIG position, use control to adjust voltagefrom 10 to 38 volts.

7 Inductance/Dig Control

Control adjusts Dig when a Stick or CC modeis selected on mode switch. When set to-wards minimum, short-circuit amperage atlow arc voltage is the same as normal weldingamperage. When set to max, control in-creases short-circuit amperage at low arc

voltage. This allows the operator to use avery short arc length without sticking theelectrode. As control is adjusted, the amountof Dig selected is displayed on the amps me-ter as a percentage (0 to 100%) of full range,and dig is displayed on the volts meter.

When Air-Carbon Arc mode is selected, Digis internally set to max.

Control adjusts inductance when MIG or V-Sense Feeder position is selected on modeswitch. Inductance determines the wetnessof the weld puddle. As setting is increased to-wards maximum, wetness (puddle fluidity)increases. As control is adjusted, the amountof inductance selected is displayed on theamps meter as a percentage (0 to 100%) offull range, and ind is displayed on the voltsmeter.

This control is not functional when one of theTIG modes is selected.

Change control setting to best suiteapplication.

OM-2252 Page 21

5-2. Meter Functions For CC/CV Models

The meters display the actual weld output values for approximately three secondsafter the arc is broken.

NOTE

Mode Meter Reading At Idle

Scratch Start TIG

Actual Volts (OCV) Preset Amps

V A

80.0 85

Lift-Arc TIG(GTAW)

V A

Actual Volts Preset Amps

8.0 85

Air Carbon Arc

V A

Actual Volts (OCV) Preset Amps

80.0 85

TIG (GTAW)

Blank Preset Amps

V A

85

MIG (GMAW)

Preset Volts Blank

V A

24.5

CC

Blank Preset Amps

V A

85

Stick (SMAW)

Actual Volts (OCV) Preset Amps

V A

80.0 85

Voltage-SensingWirefeeder

Flashes OCV And Preset Volts Blank

V A

80.0

5-3. Lift-Arc TIG Procedure For CC/CV ModelsWith Mode switch in the Lift-Arc TIGposition, start an arc as follows:

1 TIG Electrode

2 Workpiece

Touch tungsten electrode to work-piece at weld start point, holdelectrode to workpiece for 1-2seconds, and slowly lift electrode.An arc will form when electrode islifted.

Normal open-circuit voltage is notpresent before tungsten electrodetouches workpiece; only a lowsensing voltage is present betweenelectrode and workpiece. Thesolid-state output contactor doesnot energize until after electrode istouching workpiece. This allowselectrode to touch workpiece with-out overheating, sticking, or gettingcontaminated.

1

1 2SecondsTouch

Do NOT Strike Like A Match!

2

Ref. S-156 279

OM-2252 Page 22

SECTION 6 MAINTENANCE & TROUBLESHOOTING6-1. Routine Maintenance

Disconnect input power before maintaining.

3 Months

Replaceunreadablelabels.

Repair orreplacecrackedweld cable.

Clean andtighten weldterminals.

6 Months

Blow out orvacuum inside.During heavyservice, clean monthly.

OR

6-2. Fuse F1

Ref. 800 101-C

Disconnect input power be-fore opening rear accessdoor.

1 Fuse F1 (See Parts List ForRating)

Fuse F1 protects control transform-er from overload. If F1 opens, weldoutput and fan motor stops. Re-place F1.

Close door when finished.1

Tools Needed:

3/8 in

OM-2252 Page 23

6-3. Voltmeter/Ammeter Help Displays

All directions are in reference tothe front of the unit. All circuitryreferred to is located inside theunit.

1 Help 0 Display

Indicates a shorted thermistor in thetransformer of the unit. If this dis-play is shown, contact a FactoryAuthorized Service Agent.

2 Help 2 Display

Indicates a malfunction in the ther-mal protection circuitry located onthe transformer of the unit. If thisdisplay is shown, contact a FactoryAuthorized Service Agent.

3 Help 3 Display

Indicates the transformer of the unithas overheated. The unit has shutdown to allow the fan to cool it (seeSection 4-2). Operation will contin-ue when the unit has cooled.

4 Help 4 Display

Indicates a malfunction in the ther-mal protection circuitry located onthe secondary heat sink of the unit.If this display is shown, contact aFactory Authorized Service Agent.

5 Help 5 Display

Indicates the secondary heat sinkof the unit has overheated. The unithas shut down to allow the fan tocool it (see Section 4-2). Operationwill continue when the unit hascooled.

6 Help 6 Display

Indicates that the input voltage istoo low and the unit has automati-cally shut down. Operation will con-tinue when the voltage is within15% of the operating range. If thisdisplay is shown, have an electri-cian check the input voltage.

7 Help 7 Display

Indicates that the input voltage istoo high and the unit has automati-cally shut down. Operation will con-tinue when the voltage is within15% of the operating range. If thisdisplay is shown, have an electri-cian check the input voltage.

8 Help 9 Display

Indicates a shorted thermistor onthe secondary heat sink of the unit.If this display is shown, contact aFactory Authorized Service Agent.

2AV

3AV

HE.L P2

HE.L P3

4AV

HE.L P4

5AV

HE.L P5

6AV

HE.L P6

7AV

HE.L P7

AV

HE.L P0

AV

HE.L P98

1

OM-2252 Page 24

6-4. Troubleshooting

Trouble Remedy

No weld output; unit completely inop-erative; pilot light PL1 off.

Place line disconnect device in On position (see Section 4-14).

Check for open line fuse(s), and replace if open (see Section 4-14).

Check for proper input power connections (see Section 4-14).

Check for proper jumper link position (see Section 4-13).

Check fuse F1, and replace if necessary (see Section 6-2).

Meter displays a HELP message. If meters display a HELP message, see Section 6-3.

No weld output; pilot light PL1 on. Check for open line fuse(s), and replace if open (see Section 4-14).p p g

Check for proper input power connections (see Section 4-14).

Check for proper jumper link position (see Section 4-13).

Unit overheated. Allow unit to cool with fan On (see Section 4-2).

If using remote control, place Panel/Remote control switch in Remote position, and connect remotecontrol (see Sections 4-11 and 5-1). If remote is not being used, place switch in Panel position (seeSection 5-1).

Check, repair, or replace remote control.

Limited weld output and lowopen-circuit voltage

Check position of Panel/Remote control switch (see Section 5-1).open-circuit voltage.

Check for open line fuse(s), and replace if open (see Section 4-14).

Check for proper input power connections (see Section 4-14).

Check for proper jumper link position (see Section 4-13).

Clean and tighten all weld output connections.

Unit provides only maximum or mini-mum weld output.

Check position of Panel/Remote control switch (see Section 5-1).

Have Factory Authorized Service Agent check control board PC1, front panel display board PC2, andhall device HD1.

Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-8).

Clean and tighten all weld connections.

Check wire feeder installation according to Owners Manual.

Check position of Mode switch (see Section 5-1).

Have Factory Authorized Service Agent check control board PC1, front panel display board PC2, andhall device HD1.

No 115 volts AC output at duplex re-ceptacle or Remote 14 receptacle.

Reset circuit breaker CB1 (see Section 4-7).

No 24 volts AC output at Remote 14receptacle.

Reset circuit breaker CB2 (see Section 4-7).

Fan not operating. Note: fan only runswhen cooling is necessary.

Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.

Wandering arc; poor control of arc di-rection.

Reduce gas flow rate.

Select proper size tungsten.

Properly prepare tungsten.

Tungsten electrode oxidizing and notremaining bright after conclusion ofweld.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

Check for water in torch, and repair torch if necessary. See torch Owners Manual.

Digital meter not working properly. Have Factory Authorized Service Agent check front panel display board PC2 and connections, and re-place if necessary.

OM-2252 Page 25

SECTION 7 ELECTRICAL DIAGRAM

218 081-E

Figure 7-1. Circuit Diagram For Dimension NT 450

OM-2252 Page 26

SECTION 8 PARTS LIST

803 896-E

Hardware is common andnot available unless listed.

1

2

3

4

567

8

9

1011

12

13

14

3

2

15

17

18

19

20

21

24

2526

27

28

29

31

30

16

22

2321

Figure 8-1. Main Assembly

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 8-1. Main Assembly

Quantity

1 Fig 8-2 PANEL, Front w/Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 217 136 LABEL,WARNING ELECTRIC SHOCK 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 +179 432 PANEL, SIDE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 179 431 COVER, TOP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 213 898 BAFFLE, AIR UPPER IGBT ASSY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 162 830 LIFT EYE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 177 279 GASKET, LIFT EYE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 162 820 BAR, MTG LIFT EYE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fig 8-4 PANEL, REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 C21,22,23 163 906 CAPACITOR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 159 034 HOLDER, FUSE MINTR 10.3MM X 33.3 TO 38.1MM PANEL MT 1. . . . . . . . . . . . . . . . . . . . . . . . 12 F1 156 065 FUSE, CRTG .5 AMP 600 V TIME DELAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 W 160 793 CONTACTOR, DEF PRP 60A 3P 24VAC COIL W/BOXLUG 1. . . . . . . . . . . . . . . . . . . . . . . . . .

OM-2252 Page 27

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 8-1. Main Assembly (Continued)

Quantity

14 TE1 159 244 PRIMARY BOX (Consisting of), 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 835 NUT, 10-32 BRASS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 038 887 STUD, PRIMARY BOARD BRS 1032 X 1.375 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010 913 WASHER, FLAT .218IDX0.460ODX.031T BRS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 038 618 LINK, JUMPER TERM BD PRI 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 212 095 BAFFLE, AIR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 T2 159 042 XFMR, CONTROL 50VA 24V 230/460/575 PRI 60HZ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 162 816 CHANNEL, UPRIGHT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 163 359 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SR1 207 663 RECTIFIER, SI DIODE 500 AMP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 T1 224 297 XFMR, POWER MAIN 230/460/575 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TH1 223 386 THERMISTOR, NTC 10K OHM @ 25 DEG C 34IN LEAD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC16,17 212 420 HOUSING RCPT+PINS, (SERVICE KIT) 3PIN/5PIN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG16,17 217 885 HOUSING, PLUG+SKTS (SERVICE KIT)3 SKT/5 SKT 1. . . . . . . . . . . . . . . . . . . . . . . . . . 21 212 316 BRACKET, MOUNTING IGBT ASSEMBLY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 179 276 BUSHING, SNAPIN NYL 1.000 ID X 1.375 MTG HOLE CENT 1. . . . . . . . . . . . . . . . . . . . . . . . . 23 Fig 8-3 ASSEMBLY, IGBT/CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 211 928 COVER, IGBT/CAPACITOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 057 358 BUSHING, SNAPIN NYL 1.000 ID X 1.375 MTG HOLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 190 512 STANDOFF, NO 632 X .640 LG .250 HEX AL FEM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PC1 222 309 CIRCUIT CARD ASSY,CONTROL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8/RC2131 204 HOUSING, PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG4/RC4 115 093 HOUSING, PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG5/RC5 115 094 HOUSING, PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG6/RC6 115 092 HOUSING, PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG7/RC7131 054 HOUSING, PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 212 592 COVER, PC BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 212 594 BAFFLE, AIR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 193 462 BRACKET, MOUNTING CONTACTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Z1 211 150 STABILIZER 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 Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2252 Page 28

803 897-F

Hardware is common andnot available unless listed.

Hardware is common andnot available unless listed.

11

12

1314

1516

18

19

20

211

2 3

4

53

4

6

26

725

89

2710

22

2223

24

28

29

Figure 8-2. Panel, Front With Components

OM-2252 Page 29

Figure 8-2. Panel, Front With Components (Fig 8-1 Item 1)

Description QuantityPartNo.

Dia.Mkgs.

ItemNo.

1 204 143 PANEL, FRONT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 POS 181 245 TERMINAL, PWR OUTPUT RED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 C4, 5 128 750 CAPACITOR, CER DISC .1 UF 500 VDC W/TERMS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 010 381 CONNECTOR, RECTIFIER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 161 303 SPRING, CPRSN .600 OD X .072 WIRE X 1.500 PLD 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 NEG 181 246 TERMINAL, PWR OUTPUT BLACK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 212 318 PLATE, CONTROL LOWER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 217 865 LABEL, WARNING ELECTRIC SHOCK AND REDUCED AIR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 160 935 CLIP, SPRING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 +172 587 COVER, OUTPUT STUD GENERIC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 S1 159 039 SWITCH, ROCKER SPDT 15A 125VAC ONNONEON ILLUM 1. . . . . . . . . . . . . . . . . . . . .

PLG 9 185 626 CONN, BODY 56 SERIES 5FEMALE TERMINALS. . . . . . . . . . . 12 174 991 KNOB, POINTER 1.250 DIA X .250 ID W/SPRING CLIP.21 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 229 448 NAMEPLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 218 080 PANEL, FRONT UPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 190 512 STANDOFF, NO 632 X .640 LG .250 HEX AL FEM 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PC2 228 791 CIRCUIT CARD ASSY, FRONT PANEL & DISPLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 115 091 HOUSING, PLG & SKTS, (SERVICE KIT) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 211 149 ELECTRONICS BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CB 1, 2 093 995 CIRCUIT BREAKER, MAN RESET 1P 15A 250VAC FRICT 2. . . . . . . . . . . . . . . . . . . . . 20 RC15 604 176 RCPT, STR DX GRD 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 211 506 RECEPTACLE, CAPACITOR W/LEADS (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC14 143 976 RCPT W/SKTS (SERVICE KIT) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOD 1 227 590 MODULE, FILTER .1MF X 9 500VDC W/GND 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG1 200 952 CONN, RECT INSULATION DISPLACEMENT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 010 494 BUSHING, SNAPIN NYL 1.375 ID X 1.750 MTG HOLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 218 352 STRAP, GROUNDING 5.50 IN LONG 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 HD1 168 829 TRANSDUCER, CURRENT 1000A MODULE MAX OPEN LOOP 1. . . . . . . . . . . . . . . . . . . 25 170 391 CONNECTOR, CIRC MS PROTECTIVE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 228 672 LABEL, WELD CABLE LUG 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 227 980 LABEL, OUTPUT TERMINAL CONNECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 222 799 CABLE,RIBBON 24 POSN 14.000 IN SKTS BE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 229 455 SWITCH, ROTARY 2 POSN 1P .10A 125VAC SOLDER 180DEG 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 Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2252 Page 30

Hardware is common andnot available unless listed.

803 937-C

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Figure 8-3. IGBT/Capacitor Assembly

OM-2252 Page 31

DescriptionPartNo.

Dia.Mkgs.

221 298

ItemNo. Quantity

Figure 8-3. IGBT/Capacitor Assembly (Fig 8-1 item 23)

1 221 301 BUS PLATE, IGBT TO CAPACITOR NEGATIVE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 221 304 STANDOFF, CONDUCTIVE BUS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 221 303 INSULATOR, BUS PLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 221 300 BUS PLATE, IGBT TO CAPACITOR POSITIVE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 R3 188 067 RESISTOR, WW FXD 100 W 200 OHM W/CLIPS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 221 299 TRAY, MOUNTING COMPONENTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 010 494 BUSHING, SNAPIN NYL 1.375 ID X 1.750 MTG HOLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 224 144 BUS BAR, IGBT OUTPUT W/FINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 223 387 ASSY, HEAT SINK/600A IGBT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 TH2 188 431 THERMISTOR, NTC 30K OHM @ 25 DEG C 27IN LEAD 1. . . . . . . . . . . . . . . . . . . . . . . . . 11 010 546 BUSHING, SNAPIN NYL .375 ID X .500 MTG HOLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C1 222 654 CAPACITOR, ELCTLT 35000 UF 100 VDC CAN 3.00DIA STUDMNT 3. . . . . . . . . . . . . . . . . 13 222 653 BRACKET, MTG CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 010 467 CONN, CLAMP CABLE 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2252 Page 32

Hardware is common and notavailable unless listed.

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803 936-A

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Figure 8-4. Panel, Rear With Components

Figure 8-4. Panel, Rear With Components (Fig 8-1 Item 9)

Description QuantityPartNo.

Dia.Mkgs.

ItemNo.

1 173 283 CHAMBER, PLENUM 14 IN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 180 165 BLADE, FAN 14 IN 3WG 28DEG .375 BORE CCW 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 162 807 PANEL, REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 168 343 HINGE, DOOR PRIMARY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 +162 818 DOOR, ACCESS PRIMARY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 217 733 LABEL, WARNING ELECTRIC SHOCK & INPUT POWER (EN/FR) 1. . . . . . . . . . . . . . . . . . . . . 7 602 177 SCREW, SET .250-20 X .250KNRLPT SCH STL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 124 274 BRACKET, MTG FAN MOTOR 1. . . . . . . . .