Arc Welding Power Source
Dimension 650
CE
OM-272476C
2016−03
Processes
Description
Multiprocess Welding
File: MULTIPROCESS
Visit our website at
www.MillerWelds.com
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Page 1: ...Arc Welding Power Source Dimension 650 CE OM 272476C 2016 03 Processes Description Multiprocess Welding File MULTIPROCESS Visit our website at www MillerWelds com t...
Page 2: ...ntinue 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...
Page 3: ...5 Remote 14 Receptacle Information 12 4 6 Supplementary Protector 13 4 7 Electrical Service Guide 13 4 8 Connecting Input Power 14 SECTION 5 GENERAL OPERATION 16 5 1 Front Panel 16 5 2 Mode Switch Set...
Page 4: ...SAW Process 31 9 2 Subarc Welding Mode SAW Process 32 SECTION 10 MAINTENANCE TROUBLESHOOTING 33 10 1 Routine Maintenance 33 10 2 Blowing Out Inside Of Unit 33 10 3 Help Displays 34 10 4 Troubleshootin...
Page 5: ...80 400V CE 907618 Council Directives 2014 35 EU Low Voltage 2014 30 EU Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equi...
Page 6: ...al exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational exposure is below the Expo...
Page 7: ...neeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC...
Page 8: ...ared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as clo...
Page 9: ...S can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for ma...
Page 10: ...PA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of...
Page 11: ...afety 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 explo...
Page 12: ...elding GMAW U2 Conventional Load Voltage Panel I2 Rated Welding Current Increase Circuit Breaker Positive Constant Voltage Shielded Metal Arc Welding SMAW U1 Primary Voltage IP Degree Of Protection I1...
Page 13: ...ections 8 2 and 8 3 Inductancecontrol influences the arc stiffness bead width and appearance and puddle fluidity in MIG Welding Modes see Section 7 2 3 3 Serial Number And Rating Label Location The se...
Page 14: ...s where the electrical power is provided by the public low voltage supply system There can be potential difficulties in ensuring electromagnetic compatibility in those locations due to con ducted as w...
Page 15: ...650 Amperes 60 Duty Cycle At 750 Amperes 6 Minutes Welding 4 Minutes Resting 25 Duty Cycle At 815 Amperes 2 1 2 Minutes Welding 7 1 2 Minutes Resting 0 100 200 300 400 500 600 700 800 900 10 100 OUTP...
Page 16: ...fting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input power s...
Page 17: ...0 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 500 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x3 0 3x95 600 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x4 0 3x120 3x4 0...
Page 18: ...hing between weld cable terminal and copper bar Make sure that the sur faces of the weld cable terminal and copper bar are clean Tools Needed 3 4 in 19 mm 1 2 3 4 5 5 4 5 Remote 14 Receptacle Informat...
Page 19: ...trical Code NEC allows the receptacle or conductor rating to be less than the rating of the circuit protection device All components of the circuit must be physically compatible See NEC articles 210 2...
Page 20: ...OM 272476 Page 14 4 8 Connecting Input Power 3 8 in Input12 2015 07 Ref 803 766 C 272 784 A 3 16 in Tools Needed GND PE Earth Ground U L1 9 1 V L2 W L3 3 6 10 8 11 12 3 1 U L1 V L2 W L3 8 6 5 7 4 2...
Page 21: ...Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief Tighten strain relief 4 Input Power Connection Block 5 Welding Power Source Grounding Ter...
Page 22: ...e 14 Receptacle 2 Left Display 3 Right Display The meters display the actual weld output values after arc initiation and remains dis played for approximately three seconds after the arc is broken 4 Ad...
Page 23: ...W Remote 14 Volts Volts MIG GMAW FCAW Remote 14 Volts Volts See Section 5 4 For Alternate Configuration Functions 5 3 Optional Low Open Circuit Voltage OCV Welding Modes Low OCV Operation The unit can...
Page 24: ...cted the remote control sets the percent age of preset amperage The Remote In Use indicator is lit while the remote control is connected C 2 This is the default configuration as shipped from the facto...
Page 25: ...rn off power before making con nections 1 Foot Control 2 Positive Weld Output Terminal 3 Remote 14 Receptacle Connect desired remote control to Remote 14 receptacle if required 4 Gas Cylinder 5 Gas Ho...
Page 26: ...is shown in the Right Display Operation The Adjust Control is used to set desired preset amperage A remote control is required to turn on the weld output If the remote control has an amperage adjustm...
Page 27: ...sensing voltage is present The sensing voltage allows the electrode to touch the workpiece without overheating sticking or getting contami nated Operation The Adjust Control is used to set desired pr...
Page 28: ...eld Output Terminal 3 Negative Weld Output Terminal 4 Ground Cable to Workpiece 5 Workpiece 6 Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder Use of shielding gas is dependant on Wire Type The connection...
Page 29: ...ired preset voltage The preset voltage can be adjusted re motely at the wire feeder if the feeder has a voltage control This voltage con trol will override the Adjust Control of preset voltage on the...
Page 30: ...3 Ground Cable to Workpiece 4 Workpiece 5 Voltage Sensing Clamp 6 Gun 7 Gun Trigger Receptacle 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on Wire Type The connection di...
Page 31: ...s between open cir cuit voltage and preset voltage Operation The Adjust Control is used to set desired preset voltage The Left Display toggling momentarily pauses while the preset voltage is ad justed...
Page 32: ...les between open cir cuit voltage and preset voltage Operation The Adjust Control is used to set desired preset voltage The Left Display toggling momentarily pauses while the preset voltage is ad just...
Page 33: ...Electrode Holder Carbon Arc For CAC A process connect carbon arc cutting torch to positive weld output termi nal 2 Electrode Holder 3 Positive Weld Output Terminal 4 Remote 14 Receptacle Connect desir...
Page 34: ...remote control has an amperage adjustment the adjustment will func tion as a percentage of the preset am perage The Remote In Use indicator will be lit Adaptive Hot Start automatically increases weld...
Page 35: ...on The Adjust Control is used to set desired preset amperage Adaptive Hot Start automatically increases welding amperage at the start of a weld This helps eliminate electrode sticking dur ing arc init...
Page 36: ...ght Display 4 Adjust Control Setup For typical system connections refer to Section 8 1 Rotate Mode Switch to Gouge position as shown The open circuit voltage is shown in the Left Display and the prese...
Page 37: ...con nections 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal 3 Ground Cable to Workpiece 4 Workpiece 5 Wire Drive Assembly 6 10 Pin Motor Control Cord 7 Saw Control 8 Flux System 9 Fl...
Page 38: ...oltage is shown in the Left Dis play SAW Controller When using Miller Electric HDC DX con troller select Dimension 652 or SubArc DC 650 for power source selection This product is not compatible with d...
Page 39: ...hs Replace Damaged Or Unreadable Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections 6 Months Blow Out Insi...
Page 40: ...ontinue when the unit has cooled Help 4 Display Indicates the auxiliary circuit has overheated The unit has shut down to allow the fan to cool it Operation will continue when the unit has cooled Help...
Page 41: ...range of variation see Section 4 7 Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 3 7 Erratic or improper weld output Use proper size and type of we...
Page 42: ...OM 272476 Page 36 SECTION 11 ELECTRICAL DIAGRAMS Figure 11 1 Circuit Diagram For Dimension 650 CC CV 380 400V...
Page 43: ...OM 272476 Page 37 272 471 A...
Page 44: ...PARTS LIST Hardware is common and not available unless listed 272 811 A 4 Fig 12 2 12 8 Fig 12 4 5 32 Fig 12 3 23 11 3 15 2 25 1 24 14 17 16 27 13 21 10 9 20 22 7 31 26 18 6 28 30 33 29 19 34 Fig 12 5...
Page 45: ...ontactor 1 22 W1 180270 Contactor Def Prp 40A 3P 24 VAC Coil W Boxlug 1 23 FM3 183918 Motor Fan 24VDC 3000 RPM 43 Cfm W 10 Ohm Resistor 1 24 263623 Bracket Mtg Fan 1 25 267340 Bracket HF Lead Tray 1 2...
Page 46: ...C1 263562 Circuit Card Assy Front Panel Display W Program 1 PLG56 241167 Housing Plug Skts Service Kit 1 PLG59 PLG53 241168 Housing Plug Skts Service Kit 2 PLG60 241169 Housing Plug Skts Service Kit 1...
Page 47: ...03 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole Cent 2 7 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 8 245520 Bushing Snap in Nyl 1 062 Id X 1 500 Mtg Hole Cent 1 9 264199 Stand off Insul Bu...
Page 48: ...et Mtg Lem 1 8 263559 Terminal Pwr Output Red 1 9 196355 Insulator Screw 6 10 T1 269226 Xfmr Assy Hf 1 11 263556 Insulator Heatsink 1 12 199840 Bus Bar Diode 4 13 D1 D4 269909 Kit Diode Power Module V...
Page 49: ...Bracket Mtg Primary Block Cover 1 9 265204 Ring Aux Power Receptacle 1 10 214918 Rcpt Str Dx Grd 2P3W 20A 125V 5 20R 1 11 C17 270072 Capacitor Assy W Lead 1 12 CB2 083432 Supplementary Pro Man Reset...
Page 50: ...Notes...
Page 51: ...ns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components suc...
Page 52: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...
