Miller 652

OM-278 163 769AC
2007−08
Processes
Multiprocess Welding
Description
Arc Welding Power Source
Dimension
™
652 and 812
File: Multi-Process
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www.MillerWelds.com
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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 9001:2000 Quality Warranty and service information for your
System 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
www.MillerWelds.com on the web.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 3
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-1. General Precautionary Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-2. Input Connection Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3. Electric Shock And Airflow Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-4. Nameplate Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-6. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-7. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-7. 115 VAC Receptacle And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-8. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-9. Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-10. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-11. Mig (GMAW) Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-12. Mig (GMAW) And Flux Cored (FCAW) Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-13. TIG (GTAW) Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-14. Remote 14 Receptacle RC8 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-15. Connecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-17. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-18. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-1. Controls (Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-2. Controls (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-3. Short Circuit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPTIONS AND ACCESSORIES
WARRANTY

Declaration of Conformity for
European Community (CE) Products
NOTE This information is provided for units with CE certification (see rating label on unit).
Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: (920) 734-9821 Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product: Dimension™ 812

conforms to the following Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1

(April 1995 − Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: August 1995
dec_stat_6/05

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
7
Protect yourself and others from injury — read and follow these precautions.
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 for damage or bare wiring −
repair this unit. replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
During operation, keep everybody, especially children, away. D Do not use worn, damaged, undersized, or poorly spliced 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
with a separate cable.
Touching live electrical parts can cause fatal shocks D Do not touch electrode if you are in contact with the work, ground,
or severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also D Do not touch electrode holders connected to two welding ma-
live when power is on. In semiautomatic or automatic wire welding, the chines at the same time since double open-circuit voltage will be
wire, wire reel, drive roll housing, and all metal parts touching the present.
welding wire are 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 Wear dry, hole-free insulating gloves and body protection.
D Keep all panels and covers securely in place.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work D Clamp work cable with good metal-to-metal contact to workpiece
or ground. or worktable as near the weld as practical.
D Do not use AC output in damp areas, if movement is confined, or if D Insulate work clamp when not connected to workpiece to prevent
there is a danger of falling. contact with any metal object.
D Use AC output ONLY if required for the welding process. D Do not connect more than one electrode or work cable to any
D If AC output is required, use remote output control if present on single weld output terminal.
unit.
D Additional safety precautions are required when any of the follow-
SIGNIFICANT DC VOLTAGE exists in inverter-type
ing electrically hazardous conditions are present: in damp welding power sources after removal of input
locations or while wearing wet clothing; on metal structures such power.
as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt- HOT PARTS can cause severe burns.
age. In most situations, use of a DC, constant voltage wire welder
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 D Allow cooling period before working on gun or
servicing this equipment. Lockout/tagout input power according to torch.
OSHA 29 CFR 1910.147 (see Safety Standards). D To handle hot parts, use proper tools and/or
D Properly install and ground this equipment according to its wear heavy, insulated welding gloves and
Owner’s Manual and national, state, and local codes. clothing to prevent burns.
OM-278 Page 1

D Do not use welder to thaw frozen pipes.
FUMES AND GASES can be hazardous.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your D Wear oil-free protective garments such as leather gloves, heavy
health. shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
D Keep your head out of the fumes. Do not breathe the fumes. from your person before doing any welding.
D If inside, ventilate the area and/or use local forced ventilation at the D After completion of work, inspect area to ensure it is free of sparks,
arc to remove welding fumes and gases. glowing embers, and flames.
D If ventilation is poor, wear an approved air-supplied respirator. D Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables, D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
coatings, cleaners, and degreasers. for hot work and have a fire watcher and extinguisher nearby.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
FLYING METAL or DIRT can injure eyes.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
ing air is safe.
they can throw off slag.
D Do not weld in locations near degreasing, cleaning, or spraying op-
D Wear approved safety glasses with side
erations. The heat and rays of the arc can react with vapors to form
shields even under your welding helmet.
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
BUILDUP OF GAS can injure or kill.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements D Shut off shielding gas supply when not in use.
can give off toxic fumes if welded. D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.

MAGNETIC FIELDS can affect Implanted
Arc rays from the welding process produce intense Medical Devices.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the D Wearers of Pacemakers and other Implanted
weld.
Medical Devices should keep away.
D Wear an approved welding helmet fitted with a proper shade of fil- D Implanted Medical Device wearers should consult their doctor
ter lenses to protect your face and eyes when welding or watching and the device manufacturer before going near arc welding, spot
(see ANSI Z49.1 and Z87.1 listed in Safety Standards). welding, gouging, plasma arc cutting, or induction heating
D Wear approved safety glasses with side shields under your operations.
helmet.
D Use protective screens or barriers to protect others from flash, NOISE can damage hearing.
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant mate- Noise from some processes or equipment can
rial (leather, heavy cotton, or wool) and foot protection. damage hearing.
D Wear approved ear protection if noise level is
WELDING can cause fire or explosion. 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
workpiece, and hot equipment can cause fires and Shielding gas cylinders contain gas under high
burns. Accidental contact of electrode to metal objects can cause pressure. If damaged, a cylinder can explode. Since
sparks, explosion, overheating, or fire. Check and be sure the area is gas cylinders are normally part of the welding
safe before doing any welding. process, be sure to treat them carefully.
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 D Use only correct shielding gas cylinders, regulators, hoses, and fit-
cause fire on the hidden side. tings designed for the specific application; maintain them and
D Do not weld on closed containers such as tanks, drums, or pipes, associated parts in good condition.
unless they are properly prepared according to AWS F4.1 (see D Turn face away from valve outlet when opening cylinder valve.
Safety Standards). D Keep protective cap in place over valve except when cylinder is in
D Do not weld where the atmosphere may contain flammable dust, use or connected for use.
gas, or liquid vapors (such as gasoline). D Use the right equipment, correct procedures, and sufficient num-
D Connect work cable to the work as close to the welding area as ber of persons to lift and move cylinders.
practical to prevent welding current from traveling long, possibly D Read and follow instructions on compressed gas cylinders,
unknown paths and causing electric shock, sparks, and fire associated equipment, and Compressed Gas Association (CGA)
hazards. publication P-1 listed in Safety Standards.
OM-278 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

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 as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
FALLING UNIT can cause injury. finished and before reconnecting input power.
D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories. READ INSTRUCTIONS.
D Use equipment of adequate capacity to lift and
support unit. D Read Owner’s Manual before using or servic-
D If using lift forks to move unit, be sure forks are ing unit.
long enough to extend beyond opposite side of D Use only genuine replacement parts from the
unit. manufacturer.
OVERUSE can cause OVERHEATING

H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D High-frequency (H.F.) can interfere with radio
D Reduce current or reduce duty cycle before navigation, safety services, computers, and
starting to weld again. communications equipment.
D Do not block or filter airflow to unit. D Have only qualified persons familiar with
electronic equipment perform this installation.
FLYING SPARKS can cause injury. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
D Wear a face shield to protect eyes and face. tion.
D Shape tungsten electrode only on grinder with D If notified by the FCC about interference, stop using the
proper guards in a safe location wearing proper equipment at once.
face, hand, and body protection. D Have the installation regularly checked and maintained.
D Sparks can cause fires — keep flammables away. D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
STATIC (ESD) can damage PC boards. minimize the possibility of interference.
D Put on grounded wrist strap BEFORE handling

boards or parts. ARC WELDING can cause interference.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards. D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
MOVING PARTS can cause injury. such as robots.
D Be sure all equipment in the welding area is
D Keep away from moving parts.
electromagnetically compatible.
D Keep away from pinch points such as drive
rolls. D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
WELDING WIRE can cause injury. tronic equipment.
D Be sure this welding machine is installed and grounded
D Do not press gun trigger until instructed to do
according to this manual.
so.
D If interference still occurs, the user must take extra measures
D Do not point gun toward any part of the body,
such as moving the welding machine, using shielded cables,
other people, or any metal when threading
using line filters, or shielding the work area.
welding wire.
OM-278 Page 3

1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.
1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
from Global Engineering Documents (phone: 1-877-413-5184, website: 416-747-4044, website: www.csa-international.org).
www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec-
Recommended Safe Practices for the Preparation for Welding and Cut- tion, ANSI Standard Z87.1, from American National Standards Institute,
ting of Containers and Piping, American Welding Society Standard 25 West 43rd Street, New York, NY 10036–8002 (phone:
AWS F4.1, from Global Engineering Documents (phone: 212-642-4900, website: www.ansi.org).
1-877-413-5184, website: www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
National Electrical Code, NFPA Standard 70, from National Fire Protec- Work, NFPA Standard 51B, from National Fire Protection Association,
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
617-770-3000, website: www.nfpa.org and www. sparky.org). site: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
from Compressed Gas Association, 4221 Walney Road, 5th Floor, and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Code for Safety in Welding and Cutting, CSA Standard W117.2, from (phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Canadian Standards Association, Standards Sales, 5060 Mississauga, Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them, or using a
Electric And Magnetic Fields cable cover.
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
5. Connect work clamp to workpiece as close to the weld as possi-
frequency electric and magnetic fields is a human-health hazard.”
ble.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Implanted Medical Devices:
may wish to minimize your exposure to electromagnetic fields when Implanted Medical Device wearers should consult their doctor and the
welding or cutting. device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
To reduce magnetic fields in the workplace, use the following If cleared by your doctor, then following the above procedures is recom-
procedures: mended.
OM-278 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2007−04
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
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
NOTE − 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

(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
Les symboles représentés ci-dessous sont utilisés dans ce ma- souder AC à tension à vide réduite. Dans la plupart des situations,
nuel pour attirer l’attention et identifier les dangers possibles. En l’utilisation d’un poste à souder DC à fil à tension constante est re-
présence de l’un de ces symboles, prendre garde et suivre les commandée. En outre, ne pas travailler seul !
instructions afférentes pour éviter tout risque. Les instructions
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
en matière de sécurité indiquées ci-dessous ne constituent
stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
qu’un sommaire des instructions de sécurité plus complètes
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
fournies dans les normes de sécurité énumérées dans la Sec-
mes de sécurité).
tion 2-5. Lire et observer toutes les normes de sécurité.
D Installer le poste correctement et le mettre à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
Seul un personnel qualifié est autorisé à installer, faire fonc- nationales, provinciales et locales.
tionner, entretenir et réparer cet appareil. D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
Pendant le fonctionnement, maintenir à distance toutes les raccordé à la borne de terre du sectionneur ou que la fiche du
personnes, notamment les enfants de l’appareil. cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
UNE DÉCHARGE ÉLECTRIQUE peut teur de mise à la terre approprié et contre-vérifier les connexions.
entraîner la mort. D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
Le contact d’organes électriques sous tension peut protégez−les contre les étincelles et les pièces métalliques
provoquer des accidents mortels ou des brûlures chaudes.
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la D Vérifier fréquemment le cordon d’alimentation afin de s’assurer
sortie. Le circuit d’alimentation et les circuits internes de la machine qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
sont également sous tension lorsque l’alimentation est sur Marche. Un fil à nu peut entraîner la mort.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
avec le fil sont sous tension électrique. Un équipement installé ou mis D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
à la terre de manière incorrecte ou impropre constitue un danger. sante ou mal épissés.
D Ne pas toucher aux pièces électriques sous tension. D Ne pas enrouler les câbles autour du corps.
D Porter des gants isolants et des vêtements de protection secs et D Si la pièce soudée doit être mise à la terre, le faire directement
sans trous. avec un câble distinct.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou D Ne pas toucher l’électrode quand on est en contact avec la pièce,
des tapis assez grands afin d’éviter tout contact physique avec la la terre ou une électrode provenant d’une autre machine.
pièce à couper ou le sol. D Ne pas toucher des porte électrodes connectés à deux machines
D Ne pas se servir de source électrique à courant électrique dans les en même temps à cause de la présence d’une tension à vide dou-
zones humides, dans les endroits confinés ou là où on risque de blée.
tomber. D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
D Se servir d’une source électrique à courant électrique UNIQUE- champ les pièces endommagées. Entretenir l’appareil
MENT si le procédé de soudage le demande. conformément à ce manuel.
D Si l’utilisation d’une source électrique à courant électrique s’avère D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
nécessaire, se servir de la fonction de télécommande si l’appareil D S’assurer que tous les panneaux et couvercles sont correctement
en est équipé. en place.
D D’autres consignes de sécurité sont nécessaires dans les condi- D Fixer le câble de retour de façon à obtenir un bon contact métal-
tions suivantes : risques électriques dans un environnement métal avec la pièce à souder ou la table de travail, le plus près
humide ou si l’on porte des vêtements mouillés ; sur des structures possible de la soudure.
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque D Isoler la pince de masse quand pas mis à la pièce pour éviter le
élevé de contact inévitable ou accidentel avec la pièce à souder ou contact avec tout objet métallique.
le sol. Dans ces conditions, utiliser les équipements suivants, D Ne pas raccorder plus d’une électrode ou plus d’un câble de
dans l’ordre indiqué : 1) un poste à souder DC à tension constante masse à une même borne de sortie de soudage.
OM-278 Page 1

Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in
les sources de soudage onduleur quand on a cendie ou une explosion.
coupé l’alimentation.
Le soudage effectué sur des conteneurs fermés tel
D Arrêter les convertisseurs, débrancher le courant électrique et
que des réservoirs, tambours ou des conduites peu
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces. provoquer leur éclatement. Des étincelles peuven
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
DES PIÈCES CHAUDES peuvent des brûlures. Le contact accidentel de l’électrode avec des objet
provoquer des brûlures graves. métalliques peut provoquer des étincelles, une explosion, un surchauf
D Ne pas toucher à mains nues les parties fement ou un incendie. Avant de commencer le soudage, vérifier e
chaudes. s’assurer que l’endroit ne présente pas de danger.
D Prévoir une période de refroidissement avant de
travailler à l’équipement. D Déplacer toutes les substances inflammables à une distance de
D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
dés et porter des gants de soudage et des vêtements épais pour soigneusement avec des protections homologués.
éviter les brûlures. D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent être D Se protéger et d’autres personnes de la projection d’étincelles et
dangereux. de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
Le soudage génère des fumées et des gaz. Leur facilement passer dans d’autres zones en traversant de petites
inhalation peut être dangereux pour votre santé. fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
D Eloigner votre tête des fumées. Ne pas respirer les fumées. proximité.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au D Le soudage effectué sur un plafond, plancher, paroi ou séparation
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs D Ne pas effectuer le soudage sur des conteneurs fermés tels que
approuvé. des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor-
D Lire et comprendre les spécifications de sécurité des matériaux mes de sécurité).
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais- D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
seurs. peurs inflammables (vapeur d’essence, par exemple).
D Travailler dans un espace fermé seulement s’il est bien ventilé ou D Brancher le câble de masse sur la pièce le plus près possible de la
en portant un respirateur à alimentation d’air. Demander toujours à zone de soudage pour éviter le transport du courant sur une
un surveillant dûment formé de se tenir à proximité. Des fumées et longue distance par des chemins inconnus éventuels en provo-
des gaz de soudage peuvent déplacer l’air et abaisser le niveau quant des risques d’électrocution, d’étincelles et d’incendie.
d’oxygène provoquant des blessures ou des accidents mortels. D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
S’assurer que l’air de respiration ne présente aucun danger. lées.
D Ne pas souder dans des endroits situés à proximité d’opérations D En cas de non utilisation, enlever la baguette d’électrode du porte-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et électrode ou couper le fil à la pointe de contact.
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
mer des gaz hautement toxiques et irritants. D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier revers, des chaussures hautes et un couvre chef.
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit D Avant de souder, retirer toute substance combustible de vos po-
bien ventilé, et en portant un respirateur à alimentation d’air. Les ches telles qu’un allumeur au butane ou des allumettes.
revêtements et tous les métaux renfermant ces éléments peuvent D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
dégager des fumées toxiques en cas de soudage. trace d’étincelles incandescentes ni de flammes.
LES RAYONS DE L’ARC peuvent pro D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
voquer des brûlures dans les yeux e
sur la peau. D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
soudage. NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). DES PIECES DE METAL ou DES SA-
D Porter des lunettes de sécurité avec écrans latéraux même sous LETES peuvent provoquer des bles-
votre casque. sures dans les yeux.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements D Le soudage, l’écaillement, le passage de la pièce à la brosse en
et les étincelles ; prévenir toute personne sur les lieux de ne pas fil de fer, et le meulage génèrent des étincelles et des particules
regarder l’arc. métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des vêtements confectionnés avec des matières résistan- D Porter des lunettes de sécurité avec écrans latéraux ou un écran
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de facial.
protection.
OM-278 Page 2

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
LES ACCUMULATIONS DE GAZ des chocs mécaniques, des dommages physiques, du laitier, des
risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs.
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas D Placer les bouteilles debout en les fixant dans un support station-
de non-utilisation. naire ou dans un porte-bouteilles pour les empêcher de tomber ou
D Veiller toujours à bien aérer les espaces confi- de se renverser.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux. D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Porteur de simulateur cardiaque ou autre im- D Une électrode de soudage ne doit jamais entrer en contact avec
plants médicaux, rester à distance. une bouteille.
D Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou- D Ne jamais souder une bouteille pressurisée − risque d’explosion.
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
LE BRUIT peut endommager l’ouïe. les maintenir ainsi que les éléments associés en bon état.
Le bruit des processus et des équipements peut D Détourner votre visage du détendeur-régulateur lorsque vous
affecter l’ouïe. ouvrez la soupape de la bouteille.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé. D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
LES BOUTEILLES peuvent exploser D Utiliser les équipements corrects, les bonnes procédures et suffi-
si elles sont endommagées. samment de personnes pour soulever et déplacer les bouteilles.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma- D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
gée, elle peut exploser. Du fait que les bouteilles de l’équipement connexe et le dépliant P-1 de la CGA (Compressed
gaz font normalement partie du procédé de sou- Gas Association) mentionné dans les principales normes de sécu-
dage, les manipuler avec précaution. rité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO- LES ÉTINCELLES VOLANTES ris-

SION. quent de provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou D Porter un écran facial pour protéger le visage et
à proximité de surfaces inflammables. les yeux.
D Ne pas installer l’appareil à proximité de pro- D Affûter l’électrode au tungstène uniquement à la
duits inflammables. meuleuse dotée de protecteurs. Cette manœuv-
D Ne pas surcharger l’installation électrique − s’assurer que re est à exécuter dans un endroit sûr lorsque l’on
l’alimentation est correctement dimensionnée et protégée avant porte l’équipement homologué de protection du
de mettre l’appareil en service. visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute sub-
stance inflammable.
LA CHUTE DE L’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour LES CHARGES ÉLECTROSTATI-
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire. QUES peuvent endommager les
D Utiliser un équipement de levage de capacité
circuits imprimés.
suffisante pour lever l’appareil. D Établir la connexion avec la barrette de terre
D En utilisant des fourches de levage pour déplacer l’unité, s’assu- avant de manipuler des cartes ou des pièces.
rer que les fourches sont suffisamment longues pour dépasser D Utiliser des pochettes et des boîtes antistati-
du côté opposé de l’appareil. ques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
L’EMPLOI EXCESSIF peut SUR-

CHAUFFER L’ÉQUIPEMENT.
DES ORGANES MOBILES peuvent
D Prévoir une période de refroidissement ; re-
provoquer des blessures.
specter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche D Ne pas s’approcher des organes mobiles.
avant de poursuivre le soudage. D Ne pas s’approcher des points de coincement
D Ne pas obstruer les passages d’air du poste. tels que des rouleaux de commande.
OM-278 Page 3

LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ-
provoquer des blessures. QUENCE (H.F.) risque de provoquer
D Ne pas appuyer sur la gâchette avant d’en des interférences.
avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut
D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe-
sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-
geant le fil de soudage. tion, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
DES ORGANES MOBILES peuvent D L’utilisateur est tenu de faire corriger rapidement par un électricien
provoquer des blessures. qualifié les interférences résultant de l’installation.
D S’abstenir de toucher des organes mobiles tels D Si le FCC signale des interférences, arrêter immédiatement l’ap-
que des ventilateurs. pareil.
D Maintenir fermés et verrouillés les portes, pan-
neaux, recouvrements et dispositifs de protec- LE SOUDAGE À L’ARC risque de
tion. provoquer des interférences.
D Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection D L’énergie électromagnétique risque de provo-
pour l’entretien. quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et l’é-
D Remettre les portes, panneaux, recouvrements ou dispositifs de quipement commandé par ordinateur tel que
protection quand l’entretien est terminé et avant de rebrancher
les robots.
l’alimentation électrique.
D Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
LIRE LES INSTRUCTIONS. D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
D Lisez le manuel d’instructions avant l’utilisation aussi bas que possible (ex. par terre).
ou la maintenance de l’appareil. D Veiller à souder à une distance de 100 mètres de tout équipe-
D N’utiliser que les pièces de rechange recom- ment électronique sensible.
mandées par le constructeur. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D Effectuer régulièrement le contrôle et l’entretien de l’installation. D En cas d’interférences après avoir pris les mesures précéden-
D Maintenir soigneusement fermés les portes et les panneaux des tes, il incombe à l’utilisateur de prendre des mesures supplé-
sources de haute fréquence, maintenir les éclateurs à une distan- mentaires telles que le déplacement du poste, l’utilisation de câ-
ce correcte et utiliser une terre et un blindage pour réduire les bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
interférences éventuelles. teurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements

Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal- Les gaz d’échappement des moteurs contiennent des pro-
formations congénitales et, dans certains cas, des cancers. duits chimiques dont l’État de Californie reconnaît qu’ils
(Code de santé et de sécurité de Californie, chapitre 25249.5 provoquent des cancers et des malformations congénitales
et suivants) ou autres problèmes de procréation.
Pour les moteurs diesel :

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des Les gaz d’échappement des moteurs diesel et certains de
cancers et des malformations congénitales ou autres leurs composants sont reconnus par l’État de Californie com-
problèmes de procréation. Se laver les mains après manipu- me provoquant des cancers et des malformations
lation. congénitales ou autres problèmes de procréation.
OM-278 Page 4

2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org).
Internet : www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
Recommended Safe Practices for the Preparation for Welding and Cut- tion, ANSI Standard Z87.1, de American National Standards Institute,
ting of Containers and Piping, American Welding Society Standard 11 West 43rd Street, New York, NY 10036-8002 (téléphone :
AWS F4.1 de Global Engineering Documents (téléphone : 212-642-4900, site Internet : www.ansi.org).
1-877-413-5184, site Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
National Electrical Code, NFPA Standard 70, de National Fire Protec- Work, NFPA Standard 51B, de National Fire Protection Association,
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
617-770-3000, site Internet : www.nfpa.org). site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, OSHA, Occupational Safety and Health Standards for General Indus-
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
tilly, VA 20151 (téléphone : 703-788-2700, site Internet : and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
www.cganet.com). tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
Code for Safety in Welding and Cutting, CSA Standard W117.2, de ne de la région 5, Chicago, est 312-353-2220, site Internet :
Canadian Standards Association, 5060 Mississauga, Ontario, Canada www.osha.gov).
2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des 1. Garder les câbles ensemble, les torsader, les scotcher, ou les
champs magnétiques et électriques. recouvrir d’une housse.
Le courant de soudage, pendant son passage dans les câbles de sou- 2. Disposer les câbles d’un côté et à distance de l’opérateur.
dage, causera des champs électromagnétiques. Il y a eu et il y a encore 3. Ne pas courber pas et ne pas entourer pas les câbles autour de
un certain souci à propos de tels champs. Cependant, après avoir exa- votre corps.
miné plus de 500 études qui ont été faites pendant une période de 4. Garder le poste de soudage et les câbles le plus loin possible de
recherche de 17 ans, un comité spécial ruban bleu du National vous.
Research Council a conclu : « L’accumulation de preuves, suivant le 5. Connecter la pince sur la pièce aussi près que possible de la
jugement du comité, n’a pas démontré que l’exposition aux champs
soudure.
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en En ce qui concerne les implants médicaux :
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait Les porteurs d’implants doivent d’abord consulter leur médecin avant
souhaitable de réduire votre exposition aux champs électromagnéti- de s’approcher des opérations de soudage à l’arc, de soudage par
ques pendant le soudage ou le coupage. points, de gougeage, du coupage plasma ou de chauffage par induc-
Pour réduire les champs magnétiques sur le poste de travail, appliquer tion. Si le médecin approuve, il est recommandé de suivre les
les procédures suivantes : procédures précédentes.
OM-278 Page 5

OM-278 Page 6

. A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. General Precautionary Label
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
OM-278 Page 7

3-2. Input Connection Label

1/96 1 2 3 4 1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Electric shock from wiring can
kill.
3 Disconnect input plug or
power before working on
machine.
4 Read the Owner’s Manual
before working on this
machine.
5 Consult rating label for input
1 2 3 ? V power requirements, and
check power available at the
job site − they must match.
6 Read Owner’s Manual and
? V inside labels for connection
ÍÍÍÍ
points and procedures.
? A 5 7 Move jumper links as shown
ÍÍÍÍ on inside label to match

voltage at job site.
ÍÍ ÍÍÍÍ 3 8 Having a loop of extra length,
ÍÍ
connect grounding conductor
4 first.
S-179 290 9 Connect line input conductors
as shown on inside label −
double-check all connections,
jumper link positions, and
input voltage before applying
5 6 7 8 9 power.
3-3. Electric Shock And Airflow Label

1 2 3 1 Warning! Watch Out! There
are possible hazards as
2 Electric shock from wiring and
exposed weld terminals can
kill.
3 Close door before turning on
S-179 563 unit.
1/96
3-4. Nameplate Safety Symbols

1 Warning! Watch Out! There
1 1 are possible hazards as
2 Electric shock from welding
electrode or wiring can kill.
3 Sparks from arcing electrode
can cause explosion or fire −
disconnect cable for process
not in use.
4 Read Owner’s Manual for
connection procedures.
5 Electric shock from wiring can
5 6 kill.
2 3 4 6 Disconnect input power
before working on unit or
making terminal strip
connections.
Nameplate D-179 389
OM-278 Page 8

3-5. Manufacturer’s Rating Label For CE Products
. For label location

see Section 4-4.
3-6. WEEE Label (For Products Sold Within The EU)
Do not discard product (where ap-

plicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
OM-278 Page 9

3-7. Symbols And Definitions
NOTE Some symbols are found only on CE products.
A Amperes
Amperage/Voltage
Control−Panel
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Gas Metal Arc

Temperature Wire Feeder Arc Force (DIG)
Welding (GMAW)
Output Circuit Breaker Remote

V Volts
Positive High In- Positive Low In-

Negative Weld
ductance Weld ductance Weld Input
Output Terminal
Output Terminal Output Terminal
On Off Percent Direct Current
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional Load
Voltage
Line Connection
I1 I2 X
Three-Phase
Rated Welding
Primary Current Duty Cycle Transformer
Current
Rectifier
IP Degree Of
Protection
Three-Phase
S1 KVA
Hz Hertz
S
Suitable For Areas
Protective Earth
Of Increased
(Ground)
Shock Hazard
SECTION 4 − INSTALLATION
4-1. Specifications
Amperes Input at Rated Load Output,
IP Rated Amperage/ Max 50 or 60 Hz, Three-Phase
Model Welding Voltage
Rating OCV−DC 230 380 400 440 460 520 575
Output Range DC
V V V V V V V KVA KW
71 (70) VDC
50 − 815 A
650 A @ 44 In
In CC Mode 126 77 73 66 63 54 50.4 50 34.8
650 Volts DC, CC Mode**
21M 3.8* 1.9* 1.8* 1.6* 1.9* 1.1* 1.4* 1.52* 0.76*
Amp 100% Duty 40 (66) VDC
Cycle 10 − 65 V In
In
CV Mode
CV Mode**
*While idling
( ) Indicates specification differences for CE models
**Open-circuit voltage is 26 volts dc if unit is equipped with optional low open-circuit voltage.
OM-278 Page 10

4-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
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
Continuous Welding
Overheating
0 A/V
15
OR
Minutes Reduce Duty Cycle
168 918
4-3. Volt-Ampere Curves

Volt-ampere curves show mini-
mum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall be-
tween curves shown.
*High inductance connection.
A. *CC Mode B. CV Mode
80 70
SMAW GMAW
GTAW MAX
70 FCAW
60
60
50
50
DC Volts
40
DC Volts
40 MED
SMAW 30
30 ARC FORCE
20 SMAW 20
ARC FORCE
10 10
MIN
MIN MAX MIN MAX
0 0
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 700 800 900 1000
DC Amperes DC Amperes
168 916-A / 168 917-A
OM-278 Page 11

4-4. Selecting A Location

1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
1 beyond opposite side of unit.
3 Rating Label (Non CE Models
Only)
Use rating label to determine input
power needs. Label located under
OR front access door.
2 4 Rating Label (CE Models
Only)
Use rating label to determine input
power needs. Label located on rear
Location And Airflow access door
5 (see Section 3-5).
5 Line Disconnect Device
Locate unit near correct input
3
power supply.
! Special installation may be
required where gasoline or
volatile liquids are present −
18 in see NEC Article 511 or CEC
(460 mm) Section 20.
18 in
(460 mm)
OM-278 Page 12

4-5. Dimensions And Weights
Dimensions
A
A 30 in (762 mm) Including lift eye
B 23 in (584 mm)
38 in (965 mm) Including strain

C
C relief
B
D 35 in (889 mm)
F
G E 1-1/4 in (32 mm)
H
4 Holes
F 21-1/8 in (537 mm)
G 1-1/8 in (29 mm)
H 7/16 in (11 mm) Dia
Weight
E Front 545 lb (247 kg)

800 453-A / 801 530
OM-278 Page 13

4-6. Tipping
! Be careful when placing or
moving unit over uneven
surfaces.
4-7. 115 VAC Receptacle And Supplementary Protectors

! Turn Off power before
connecting to receptacle.
1 115 V 15 A AC Receptacle
RC9
Power is shared between RC9 and
3 Remote 14 receptacle RC8 (see
Section 4-15).
2 Supplementary Protector CB1
2
3 Supplementary Protector CB2
CB1 protects the 115 volts ac por-
tion of RC8 and RC9 from overload.
1 CB2 protects the 24 volts ac portion

of RC8 and Remote Power On/Off
from overload.
Press button to reset protector.
Ref. 800 166-D
4-8. Weld Output Terminals

! Turn Off power before
connecting to weld output
terminals
1 Positive High Inductance
Terminal
2 Positive Low Inductance
Terminal
3 Negative Weld Outout
Terminal
See Sections 4-11, 4-12 or 4-13 .
1 2
Ref. 800 166-D
OM-278 Page 14

4-9. Selecting Cable Sizes
NOTICE − ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
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%
Welding 60 − 100%
Duty 10 − 100% Duty Cycle
Amperes Duty Cycle
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
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
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
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 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 for the mm2 equivalent weld cable sizes. S-0007-E
4-10. Connecting Weld Output Cables
4
1
Do not place
anything between
weld cable terminal
and copper bar.
3
Tools Needed:
3/4 in (19 mm)
803 778-B
Correct Installation Incorrect Installation
! Turn off power before connecting to 1 Weld Output Terminal output terminal and secure with nut so that
weld output terminals. 2 Supplied Weld Output Terminal Nut weld cable terminal is tight against copper
3 Weld Cable Terminal bar. Do not place anything between weld
! Failure to properly connect weld cable terminal and copper bar. Make
cables may cause excessive heat 4 Copper Bar
sure that the surfaces of the weld cable
and start a fire, or damage your ma- Remove supplied nut from weld output ter- terminal and copper bar are clean.
chine. minal. Slide weld cable terminal onto weld
OM-278 Page 15

4-11. Mig (GMAW) Cable Connections
Gas Flowmeter/
Regulator
HIGH LOW
INDUCTANCE INDUCTANCE
! Turn Off power before making connections.

Polarity: For Electrode Positive (DCEP),
connect weld cables as shown. For
Electrode Negative (DCEN), typical for
+ + −
Gasless Flux Cored Welding, reverse cable
connections at welding power source.
or
. For better performance for most GMAW (DCEP and DCEN)
applications, it is recommended that weld output connec-
tions be made to the Low Inductance weld output terminal. Rear Of
Wire Feeder
OM-278 Page 16

4-12. Mig (GMAW) And Flux Cored (FCAW) Cable Connections
GMAW / FCAW
Gas Flowmeter/
Regulator
HIGH LOW
INDUCTANCE INDUCTANCE
(Gasless FCAW)
+ + −
or

Rear Of
Wire Feeder
. For better performance for most GMAW and (gas shielded)
FCAW (DCEP) applications, it is recommended that weld
output connections be made to the Low Inductance weld
output terminal. Make connections as shown.
FCAW (Gasless)
LOW
INDUCTANCE
(Gasless FCAW)
+ + −
Rear Of
Wire Feeder
. For better performance for most Gasless Flux Cored FCAW

(DCEN) applications, it is recommended that weld output
connections be made to the Low Inductance weld output ter-
minal. Make connections as shown.
OM-278 Page 17

4-13. TIG (GTAW) Cable Connections

Gas Flowmeter/
Regulator
HIGH
INDUCTANCE
+ + −

Optional HF Unit
. For better performance for most GTAW applications, it is
recommended that electrode negative (DCEN) weld output
connections be made to the high Inductance weld output ter-
minal. Make connections as shown.
4-14. Remote 14 Receptacle RC8 Information

Socket Information
A 24 volts ac. Protected by supplementary protector CB2.
24 VOLTS AC B Contact closure to A completes 24 volts ac contactor control circuit.
C Command reference; 0 to +10 volts dc (CC), +10 volts dc (CV).
REMOTE OUTPUT CONTROL D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.
F Current feedback; 1 volt per 100 amperes.
H Voltage feedback; 1 volt per 10 arc volts.
I 115 volts, 15 amperes, 60 Hz ac. Protected by supplementary protector CB1.
115 VOLTS AC
J Contact closure to I completes 115 volts ac contactor control circuit.
K Chassis common.
GND
G Circuit common for 24 and 115 volts ac circuits.
*
REMOTE POWER ON/OFF To remote On/Off switch.
switch
*
* Voltage sensing signal from Negative (−) weld output terminal.
REMOTE VOLTAGE SENSING
* Voltage sensing signal from Positive (+) weld output terminal.
* Not Used
OM-278 Page 18

4-15. Connecting Remote Control
! Turn off power before con-
necting a remote control.
1 Remote 14 Receptacle RC8
Connect remote control to RC8.
A J
K I
B
C L N H
D M G
E F
OR OR
Ref. 800 166-D
4-16. Electrical Service Guide

60 Hz Models 50 Hz Models
Input Voltage 230 460 575 380 400 440 520
Input Amperes At Rated Output 126 63 50.4 77 73 66 54
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 150 70 60 90 90 80 60
Normal Operating 3 200 90 80 125 110 100 80
Min Input Conductor Size In AWG 4 1 6 6 4 4 4 6
Max Recommended Input Conductor Length In Feet (Me- 208 328 513 335 371 449 419
ters) (64) (100) (156) (102) (113) (137) (128)
Min Grounding Conductor Size In AWG 4 6 8 8 6 6 8 8
Reference: 2005 National Electrical Code (NEC)

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” .
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.
OM-278 Page 19

4-17. Placing Jumper Links

! Disconnect and lockout/tag-
out input power before
installing or moving jumper
links.
Check input voltage available at
site.
1 Jumper Link Label
Check label − only one is on unit.
2 Jumper Links
Move jumper links to match input
voltage.
Close and secure access door, or
go on to Section 4-18.
230 VOLTS 460 VOLTS 575 VOLTS
Ref. S-174 973-B
220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS
1
(FACTORY OPTION) Ref. S-174 975-B
380 VOLTS 520 VOLTS
177 159-A
Tools Needed:
3/8 in Do not overtighten

jumper link nuts.
3/8 in
Ref. 800 103-A
OM-278 Page 20

4-18. Connecting Input Power
! Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
3 ! Disconnect and lockout/tagout input
power before connecting input con-
ductors from unit.
= GND/PE Earth Ground
9
! Make input power connections to the
welding power source first.
! Always connect green or green/yel-
8 low conductor to supply grounding
terminal first, and never to a line ter-
minal.
See rating label on unit and check input volt-
11 age available at site.
1 Input Power Conductors (Customer
10 Supplied Cord)
Select size and length of conductors using
2 Section 4-16. Conductors must comply with
4 national, state, and local electrical codes. If
applicable, use lugs of proper amperage
7 capacity and correct hole size.
Welding Power Source Input Power Con-
nections
2 Strain Relief
1
Route conductors (cord) through strain relief
and tighten screws.
3 Machine Grounding Terminal
4 Green Or Green/Yellow Grounding
IMPORTANT Conductor
3 5 Reed Switch (Ground Current Sensor)
6 Input Contactor (Optional)
Connect green or green/yellow grounding
L1 (U)
conductor to welding power source ground-
ing terminal first. If unit is equipped with op-
7 L2 (V) tional ground current sensor, route ground-
L3 (W) ing conductor through reed switch two times
4 and connect to grounding terminal.
6 Welding Power Source Line Terminals
7 Input Conductors L1 (U), L2 (V) And
L3 (W)
5 4 Connect input conductors L1 (U), L2 (V) and
3 L3 (W) to welding power source line termi-
= GND/ PE Earth Ground nals.
Close and secure access door on welding
power source.
Disconnect Device Input Power Connec-
tions
8 Disconnect Device (switch shown in
OFF position)
9 Disconnect Device (Supply)
Grounding Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Tools Needed: 10 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And
3/8 in
L3 (W) to disconnect device line terminals.
3/8 in 11 Over-Current Protection
Select type and size of over-current protec-
tion using Section 4-16 (fused disconnect
switch shown).
Close and secure door on line disconnect
device. Remove lockout/tagout device, and
place switch in the On position.
800 103-C / Ref. 801 116-A
OM-278 Page 21

SECTION 5 − OPERATION
5-1. Controls (Non CE Models)
3 4
1 2
8 7
6 5
Ref. 184 939
1 Arc Force (Dig) Control tance weld output terminal (see Section display actual output voltage and amperage
Control increases SMAW short-circuit 4-9). with contactor on.
amperage which allows the operator to use 3 Amperage/Voltage Adjustment Control 5 Power Switch With Indicator Light
a very short arc length without sticking the 6 High Temperature Shutdown Light
electrode. When Process Selector switch is in the
SMAW/GTAW position, turn control clock- 7 Remote Amperage/Voltage Control
Set control at 0 for normal welding amperage Switch
wise to increase amperage. Read amperage
and GTAW applications. Turn clockwise to
from outer scale of control. When Process For front panel control, place switch in Panel
increase short-circuit amperage.
Selector switch is in the GMAW position, turn position. For remote control, place switch in
2 Process Selector Switch control clockwise to increase voltage. Volt- Remote position, and connect remote de-
• GMAW Mode: For use with flux Cored meter value changes as control knob is vice (see Section 4-15).
(FCAW) or submerged arc (SAW) applica- turned. Control can be adjusted while 8 Output Switch (Contactor)
tions. welding.
For front panel control of output, place switch
• SMAW (Hot Start On) Mode: Hot Start is 4 Digital Meters in Panel position. For remote control of out-
energized for Stick (SMAW). When Hot put, place switch in Remote position, and
Start is energized, higher short circuit am- With Process Selector switch in the SMAW/
connect remote device (see
perage aids in arc starting. NOTE: use the GTAW position, digital meters will read 0
Section 4-15).
Positive (+) High Inductance weld output (zero) with contactor off. Digital meters will
terminal (see Section 4-9). display actual output voltage and amperage ! Weld output studs are energized only
with contactor on. when Output switch is in On position,
• SMAW (Hot Start Off) Mode: For use with or while welding.
TIG (GTAW), scratch start only, or sub- With Process Selector switch in the GMAW
merged arc (SAW) applications. NOTE: position, voltmeter displays preset voltage ! Turn Off power before connecting re-
for GTAW, use the Positive (+) High Induc- with contactor off. Voltmeter and ammeter mote device.
OM-278 Page 22

5-2. Controls (CE Models)
3 4
1 2
8 7
6 5
Ref. 184 936
1 Arc Force (Dig) Control tance weld output terminal (see Section display actual output voltage and amperage
Control increases SMAW short-circuit 4-9). with contactor on.
amperage which allows the operator to use 3 Amperage/Voltage Adjustment Control 5 Power Switch With Indicator Light
a very short arc length without sticking the 6 High Temperature Shutdown Light
electrode. When Process Selector switch is in the
SMAW/GTAW position, turn control clock- 7 Remote Amperage/Voltage Control
Set control at 0 for normal welding amperage Switch
wise to increase amperage. Read amperage
and GTAW applications. Turn clockwise to For front panel control, place switch in Panel
from outer scale of control. When Process
increase short-circuit amperage. position. For remote control, place switch in
Selector switch is in the GMAW position, turn
2 Process Selector Switch control clockwise to increase voltage. Volt- Remote position, and connect remote de-
• GMAW Mode: For use with flux Cored meter value changes as control knob is vice (see Section 4-15).
(FCAW) or submerged arc (SAW) applica- turned. Control can be adjusted while 8 Output Switch (Contactor)
tions. welding. For front panel control of output, place switch
• SMAW (Hot Start On) Mode: Hot Start is 4 Digital Meters in Panel position. For remote control of out-
energized for Stick (SMAW). When Hot put, place switch in Remote position, and
Start is energized, higher short circuit am- With Process Selector switch in the SMAW/
connect remote device (see
perage aids in arc starting. NOTE: use the GTAW position, digital meters will read 0
Section 4-15).
Positive (+) High Inductance weld output (zero) with contactor off. Digital meters will
terminal (see Section 4-9). display actual output voltage and amperage ! Weld output studs are energized only
with contactor on. when Output switch is in On position,
• SMAW (Hot Start Off) Mode: For use with
or while welding.
TIG (GTAW), scratch start only, or sub- With Process Selector switch in the GMAW
merged arc (SAW) applications. NOTE: position, voltmeter displays preset voltage ! Turn Off power before connecting re-
for GTAW, use the Positive (+) High Induc- with contactor off. Voltmeter and ammeter mote device.
OM-278 Page 23

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance
! Disconnect power before maintaining.
3 Months
Replace Repair or Clean and

unreadable replace tighten weld
labels. cracked weld terminals.
cable.
6 Months
Blow out or vacuum inside.

During heavy service, clean monthly.
OR
6-2. Fuse F1
! Disconnect and lockout/tag-
out input power before
checking or changing fuse.
1 Fuse F1 (See Parts List For
Rating)
Fuse F1 protects control transform-
er from overload. If F1 opens, weld
1 output and fan motor stops. Re-
place F1.
Close and secure access door.
Tools Needed:
3/8 in
Ref. 800 101-C
6-3. Short Circuit Shutdown
When contact tip is shorted and sticks to workpiece, the unit output falls to a safe operating level. To resume operation,
release gun trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged.
Turn On unit to continue operation.
OM-278 Page 24

6-4. Troubleshooting
Trouble Remedy
No weld output; unit completely Place line disconnect device in On position (see Section 4-18).
inoperative; pilot light PL1 off.
Check for open line fuse(s), and replace if open (see Section 4-18).
Check for proper input power connections (see Section 4-18).
Check for proper jumper link position (see Section 4-17).
Check fuse F1, and replace if necessary (see Section 6-2).
No weld output; power switch pilot light Unit overheated. Allow unit to cool with fan On (see Section 4-2).
on.
If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote
control (see Sections 4-14 and 4-15). If remote is not being used, place switch in On position (see
Section 5-1).
Check, repair, or replace remote control.
No weld output;
p power
p switch pilot
p light
g Check for proper input power connections (see Section 4-18).
on; fan
fa off.
ff
Check for open line fuse(s), and replace if open, or reset circuit breaker (see Section 4-18).
Turn power switch off then back on. If no output condition remains, have Factory Authorized Service
agent check SCR’s.
Limited weld output and low Check position of Remote Amperage/Voltage Control switch (see Section 5-1).
open-circuit voltage.
Check for open line fuse(s), and replace if open (see Section 4-18).
Check for proper input power connections (see Section 4-18).
Check for proper jumper link position (see Section 4-17).
Clean and tighten all weld output connections.
Unit provides only maximum or Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
minimum weld output.
Check position of Remote Amperage/Voltage Control switch (see Section 5-1).
Not able to obtain minimum output in Use high inductance weld output terminal when in CC mode to obtain minimum output (see Section
CC mode. 4-9).
Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-9).
Clean and tighten all weld connections.
Check wire feeder installation according to Owner’s Manual.
Check position of Process selector switch (see Section 5-1).
Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
No 115 volts ac output at duplex recep- Reset supplementary protector CB1 (see Section 4-7).
tacle, or Remote 14 receptacle.
No 24 volts ac output at Remote 14 re- Reset supplementary protector CB2 (see Section 4-7).
ceptacle.
Fan not operating. Note: fan only runs Check for and remove anything blocking fan movement.
when cooling is necessary.
Have Factory Authorized Service Agent check fan motor.
Wandering arc; poor control of arc Reduce gas flow rate.
direction.
Select proper size tungsten.
Properly prepare tungsten.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary. See torch Owner’s Manual.
Digital meter not working properly. Have Factory Authorized Service Agent check control board PC1 and connections, and replace if
necessary.
OM-278 Page 25

SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram
OM-278 Page 26

218 514-B
OM-278 Page 27

SECTION 8 − PARTS LIST
NOTE A complete Parts List is available on-line at www.MillerWelds.com.
8-1. Recommended Spare Parts

Dia. Part
Mkgs. No. Description Quantity
Recommended Spare Parts
. . . . . . . . . . . F1 . . . . 156 065 . . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
http://www.millerwelds.com/service/replacementparts.html
Choose Genuine Select to review spare parts requirements such
as filters, spark plugs, and fuses.
Choose Service Parts to download complete parts listing.
Notes
OM-278 Page 28

Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
Miller distributor. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Replacement Parts (No labor)
Within the warranty periods listed below, Miller will repair or * Spoolmate Spoolguns
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which Miller’s True Blue® Limited Warranty shall not apply to:
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings, relays
reliable response you Miller shall honor warranty claims on warranted equipment listed or parts that fail due to normal wear. (Exception:
need. Most replacement below in the event of such a failure within the warranty time brushes, slip rings, and relays are covered on Bobcat,
parts can be in your periods. All warranty time periods start on the delivery date of the Trailblazer, and Legend models.)
hands in 24 hours. equipment to the original end-user purchaser, and not to exceed 2. Items furnished by Miller, but manufactured by others, such
one year after the equipment is shipped to a North American as engines or trade accessories. These items are covered
Support distributor or eighteen months after the equipment is shipped to by the manufacturer’s warranty, if any.
Need fast answers to the an International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
Contact your distributor.
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
distributor and Miller is 2. 3 Years — Parts and Labor
necessary maintenance, or equipment which has been
there to help you, every * Transformer/Rectifier Power Sources used for operation outside of the specifications for the
step of the way. * Plasma Arc Cutting Power Sources equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year — Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
* Field Options BY MILLER.
(NOTE: Field options are covered under True Blue® Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year — special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
* Bernard-Branded Mig Guns (No Labor) legal rights, and other rights may be available, but may vary from
state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns/TIG Torches and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2007−01

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
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com
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.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01


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OM-278 163 769AC

Arc Welding Power Source

652 and 812

Visit our website at

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Miller Electric manufactures a full line

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Manufacturer: European Contact:

European Contact Signature:

Declares that the product: Dimension™ 812

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990

Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Insulation coordination for equipment within low-voltage systems:

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

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1-1. Symbol Usage

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

1-2. Arc Welding Hazards

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ARC RAYS can burn eyes and skin.

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

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FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

D Use lifting eye to lift unit only, NOT running

OVERUSE can cause OVERHEATING

D Put on grounded wrist strap BEFORE handling

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1-5. Principal Safety Standards

1-6. EMF Information

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2-1. Symboles utilisés

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

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

Risque D’INCENDIE OU D’EXPLO- LES ÉTINCELLES VOLANTES ris-

L’EMPLOI EXCESSIF peut SUR-

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2-4. Proposition californienne 65 Avertissements

Pour les moteurs diesel :

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2-6. Information EMF

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3-2. Input Connection Label

ÍÍÍÍ on inside label to match

ÍÍ ÍÍÍÍ 3 8 Having a loop of extra length,

3-3. Electric Shock And Airflow Label

3-4. Nameplate Safety Symbols

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. For label location