Miller Dimension 650 Owner's Manual
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Miller Dimension 650 Owner's Manual

Arc welding power source 380/400v 50/60hz ce
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OM-272476C
2016−03
Processes
Multiprocess Welding
Description
Arc Welding Power Source
t
Dimension 650
CE
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com

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  • Page 1 OM-272476C 2016−03 Processes Multiprocess Welding Description Arc Welding Power Source Dimension 650 File: MULTIPROCESS Visit our website at www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − SAW OPERATION ............. . 9-1.

  • Page 5: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
  • Page 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number DIMENSION 650 380/400V 50/60HZ CE 907618 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016 Intended use...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 8 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 11: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Notes OM-272476 Page 5...

  • Page 12: Miscellaneous Symbols And Definitions

    2-2. Miscellaneous Symbols And Definitions Negative Amperage Voltage Sensing Feeder Gas Output Alternating Current (AC) Variable Inductance Voltage Foot Control Output Gas Metal Arc Welding (GMAW) Input Voltage Conventional Load Voltage Direct Current Protective Earth (DC) (Ground) Panel Constant Current Line Connection Rated Welding Arc Force...

  • Page 13: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Features And Benefits LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input power fluctuation. Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and im- proves reliability in harsh welding environments.

  • Page 14: Dimensions And Weight

    3-5. Dimensions and Weight Weight 168 lb (76.2 Kg) 28-3/16 in. (716 mm) 24-3/16 in. (614 mm) 30-1/4 in. (768 mm) 11/16 in. (17 mm) 31-5/8 in. (803 mm) 16-11/16 in. (406 mm) 14-1/4 in. (362 mm) 269 320-A / / 269 319-A 3-6.

  • Page 15: Duty Cycle And Overheating

    3-7. Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, error message is displayed (see Section 10-3), and cooling fan runs. Wait for unit to cool and error message to clear.

  • Page 16: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 17: Selecting Cable Sizes

    **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. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-L 2015−02 4-3. Weld Output Terminals Turn off power before connecting to weld output terminals.

  • Page 18: Connecting Weld Output Cables

    4-4. Connecting Weld Output Cables Tools Needed: 3/4 in. (19 mm) 269 322-A Weld Output Terminal nals to weld output terminal with nut and Turn off power before connecting to bolt as shown, so that weld cable terminal weld output terminals. Supplied Weld Output Terminal Nut is tight against copper bar.

  • Page 19: Supplementary Protector

    4-6. Supplementary Protector 115 V 20 Amp AC Receptacle Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects duplex receptacle. CB2 protects 24 volts AC portion of Remote receptacle from overload. Press button to reset supplement- ary protector. Ref 272 773-A 4-7.

  • Page 20: Connecting Input Power

    4-8. Connecting Input Power = GND/PE Earth Ground U (L1) V (L2) W (L3) U (L1) V (L2) W (L3) Tools Needed: 3/8 in. 3/16 in. Input12 2015−07 / Ref. 803 766-C / 272 784-A OM-272476 Page 14...
  • Page 21 4-8. Connecting Input Power (Continued) national, state, and local electrical codes. If Connect input conductors to welding power Turn Off welding power source. applicable, use lugs of proper amperage source line terminals. Installation must meet all National capacity and correct hole size. Close input power cover and secure with and Local Codes −...

  • Page 22: Section 5 − General Operation

    SECTION 5 − GENERAL OPERATION 5-1. Front Panel 263561-B / Ref. 269321-B Arc Control Weld process operation sections de- The meters display the actual weld output scribe functionality of the identified items values after arc initiation and remains dis- Remote In Use Indicator (See Sections 6-1 thru 8-4).

  • Page 23: Mode Switch Settings

    5-2. Mode Switch Settings Switch Position Process Output Control Panel Adjust Remote Adjust MIG−Gas GMAW/FCAW Output On Volts Volts MIG−No Gas FCAW−S Output On Volts Volts No Remote Adjust - Stick SMAW Output On Amps Panel Only* No Remote Adjust - Gouge CAC−A Output On...

  • Page 24: Alternate Configuration Functions

    5-4. Alternate Configuration Functions The function of the remote control and panel meters can be changed on this machine. To view or change the active configuration: S Place the process selection switch into SMAW (Stick) Output-On mode. S Quickly tap (press and release) the wire feeder gun trigger or remote output on-off switch 3 to 5 times within a few seconds to view the active configuration.

  • Page 25: Section 6 − Gtaw Operation

    SECTION 6 − GTAW OPERATION 6-1. Typical Connection For GTAW Process 269 325-A Remote 14 Receptacle Gas Hose Turn off power before making con- nections. Negative (−) Weld Output Terminal Connect desired remote control to Remote 14 receptacle if required. Foot Control TIG Torch Positive (+) Weld Output Terminal...

  • Page 26: Tig Remote Welding Mode - Gtaw Process

    6-2. TIG Remote Welding Mode - GTAW Process 263 561-B Setup Operation Weld terminals energized through the remote control in TIG For typical system connections refer to The Adjust Control is used to set desired Remote welding mode. Section 6-1. preset amperage.

  • Page 27: Lift-Arc Tig Welding Mode - Gtaw Process

    6-3. Lift-Arc TIG Welding Mode - GTAW Process 12.0 263 561-B 1 − 2 “Touch” Seconds Do NOT Strike Like A Match! Setup Operation Weld terminals are energized at all times in Lift Arc TIG welding mode. For typical system connections refer to The Adjust Control is used to set desired Section 6-1.

  • Page 28: Section 7 − Gmaw/Fcaw Operation

    SECTION 7 − GMAW/FCAW OPERATION 7-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process 269 323-A Workpiece Use of shielding gas is dependant on Wire Turn off power before making Type. connections. Remote 14-Receptacle The connection diagram illustrates Wire Feeder DCEP (reverse polarity) suitable for all Positive (+) Weld Output Terminal wires except self-shielded FCAW.

  • Page 29: Mig Remote Welding Mode - Gmaw/Fcaw Process

    7-2. MIG Remote Welding Mode - GMAW/FCAW Process 25.0 263 561-B Rotate Mode Switch to MIG Remote posi- preset voltage on the welding power Weld terminals energized tion as shown. source. The Remote In Use indicator through the remote control in MIG will be lit.

  • Page 30: Typical Connection For Voltage-Sensing Feeder Gmaw/Fcaw Process

    7-3. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process 269 324-A Use of shielding gas is dependant on Wire Turn off power before making con- Type. nections. Gun Trigger Receptacle Positive (+) Weld Output Terminal The connection diagram illustrates Negative (−) Weld Output Terminal Wire Feeder DCEP (reverse polarity) suitable for all Ground Cable to Workpiece...

  • Page 31: Mig-Gas Output On Welding Mode - Gmaw/Fcaw Process

    7-4. MIG-Gas Output On Welding Mode - GMAW/FCAW Process 25.0 263 561-B Rotate Mode Switch to MIG-Gas Output Arc Control − Inductance Weld terminals are energized at all On position as shown. times in MIG-Gas Output On weld- Inductance control allows the arc charac- ing mode.

  • Page 32: Mig-No Gas Output On Welding Mode - Gmaw/Fcaw Process

    7-5. MIG-No Gas Output On Welding Mode - GMAW/FCAW Process 25.0 263 561-B Rotate Mode Switch to MIG-No Gas Output Arc Control − Inductance Weld terminals are energized at all On position as shown. times in MIG-Gas Output On weld- Inductance control allows the arc charac- ing mode.

  • Page 33: Section 8 − Smaw/Cac-A Operation

    SECTION 8 − SMAW/CAC-A OPERATION 8-1. Typical Connection For SMAW And CAC-A Process 269 326-A cutting torch to positive weld output termi- Connect desired remote control to remote Turn off power before making con- nal. 14 receptacle as required. nections. Electrode Holder Compressed Air LIne Electrode Holder...

  • Page 34: Stick Remote Welding Mode - Smaw Process

    8-2. Stick Remote Welding Mode - SMAW Process 263 561-B Operation Arc Control − Dig Weld terminals energized through the remote control in Stick The Adjust Control is used to set desired Dig control allows the arc characteristics, Remote welding mode. preset amperage.

  • Page 35: Stick-Output-On Welding Mode - Smaw Process

    8-3. Stick-Output-On Welding Mode - SMAW Process 65.0 263 561-B The open circuit voltage is shown in the Left Arc Control − Dig Weld terminals are energized at all Display and the preset amperage is shown times in Stick-Output-On welding Dig control allows the arc characteristics, in the Right Display.

  • Page 36: Gouge Mode - Cac-A Process

    8-4. Gouge Mode - CAC-A Process 65.0 263 561-B Setup Operation Weld terminals are energized at all times in Gouge mode. For typical system connections refer to The Adjust Control is used to set desired Section 8-1. preset amperage. Mode Switch Rotate Mode Switch to Gouge position as shown.

  • Page 37: Section 9 − Saw Operation

    SECTION 9 − SAW OPERATION 9-1. Typical Connection For SAW Process Power Source Back View Power Source Front View 269 792-A Ground Cable to Workpiece Saw Control Turn off power before making con- Workpiece Flux System nections. Wire Drive Assembly Flux Valve Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal...

  • Page 38: Subarc Welding Mode − Saw Process

    Adjust Control SAW Controller the Adjust Control of preset voltage on the Setup When using Miller Electric HDC DX con- welding power source. The Remote In Use For typical system connections refer to troller, select Dimension 652 or SubArc DC indicator will be lit.

  • Page 39: Section 10 − Maintenance & Troubleshooting

    SECTION 10 − MAINTENANCE & TROUBLESHOOTING 10-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Repair Or Replace Replace Cracked Replace Damaged Or Torch Body Cracked Unreadable Cables Labels Repair Or Replace Cracked Cables And Cords Clean Tighten Weld...

  • Page 40: Help Displays

    10-3. Help Displays All directions are in reference to the front HELP of the unit. All circuitry referred to is lo- cated inside the unit. HELP Help 1, 6, 7 Display HELP Indicates a malfunction in the primary power circuit. If this display is shown, contact a Fac- tory Authorized Service Agent.

  • Page 41: Troubleshooting

    10-4. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Section 4-8). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-8). Check for proper input power connections (see Section 4-8). No weld output;...

  • Page 42: Section 11 − Electrical Diagrams

    SECTION 11 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For Dimension 650 CC/CV 380/400V OM-272476 Page 36...
  • Page 43 272 471-A OM-272476 Page 37...

  • Page 44: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 8 (Fig 12-4) 34 (Fig 12-5) 4 (Fig 12-2) 32 (Fig 12-3) 272 811-A Figure 12-1. Main Assembly OM-272476 Page 38...
  • Page 45 ..Label, Miller (Not Shown) ........
  • Page 46 ....263561 Label, Nameplate Miller Dimension 650 ......
  • Page 47 Hardware is common and not available unless listed. 269 852-A Figure 12-3. Wind Tunnel, RH Item Dia. Part Mkgs. Description Quantity Figure 12-3. Wind Tunnel, RH ....263555 Heat Sink, Power Module .
  • Page 48 Hardware is common and not available unless listed. 272 803-A Figure 12-4. Wind Tunnel, LH Item Dia. Part Mkgs. Description Quantity Figure 12-4. Wind Tunnel, LH ... . . +263569 Windtunnel, Lh .
  • Page 49 Hardware is common and not available unless listed. 272 926-A Figure 12-5. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-5. Rear Panel Assembly ..272312 Circuit Card Assy, Input Filter .
  • Page 50 Notes...
  • Page 51 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 52 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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