Red-D-Arc Welderentals EXTREME 425 CC/CV Auto-Line Owner's Manual
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Red-D-Arc Welderentals EXTREME 425 CC/CV Auto-Line Owner's Manual

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OM-234 816C
2008−01
Processes
Multiprocess Welding
Description
Arc Welding Power Source
EXTREME 425
™
CC/CV Auto-Line
File: MULTIPROCESS

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Summary of Contents for Red-D-Arc Welderentals EXTREME 425 CC/CV Auto-Line

  • Page 1 OM-234 816C 2008−01 Processes Multiprocess Welding Description Arc Welding Power Source EXTREME 425 ™ CC/CV Auto-Line File: MULTIPROCESS...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 Declaration of Conformity for European Community (CE) Products 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 MILLER Europe S.r.l.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 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.
  • Page 6 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 D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    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.

  • Page 8: California Proposition 65 Warnings

    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 &...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 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.
  • Page 10 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 provoquer leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS 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 Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation.

  • Page 12: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en 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-...

  • Page 13: Principales Normes De Sécurité

    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- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :...
  • Page 14 OM-234 816 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand.
  • Page 16 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors.

  • Page 17: Weee Label (For Products Sold Within The Eu)

    3-2. 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.

  • Page 18: Section 4 − Introduction

    SECTION 4 − INTRODUCTION 4-1. Specifications Input Rated Voltage Amperage Max. RMS Amps Input at Rated Load Output, Power Output Range Range in Open- Rating 60 Hz 3-Phase at NEMA Load Voltages in CV CC Mode Circuit and Class I Rating Mode V lt Voltage...

  • Page 19: Duty Cycle And Overheating

    4-3. 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, a Help message is displayed and cooling fan runs. Wait fifteen min- utes for unit to cool. Reduce amper- age or voltage, or duty cycle before welding.

  • Page 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting a Location 24 in (610 mm) Dimensions And Weight 94.8 lb (43 kg) 17 in (432 mm) 12-1/2 in (318 mm) Lifting Handles Movement Use handles to lift unit. Hand Cart Do not move or operate unit Use cart or similar device to move where it could tip.

  • Page 21: Connecting 3-Phase Input Power

    5-2. Connecting 3-Phase Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Always connect green or green/ yellow conductor supply = GND/PE Earth Ground...

  • Page 22: Electrical Service Guide

    5-3. Electrical Service Guide NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.

  • Page 23: Weld Output Terminals And Selecting Cable Sizes

    5-4. Weld Output Terminals And Selecting Cable Sizes 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.

  • Page 24: Remote 14 Receptacle Information

    5-5. Remote 14 Receptacle Information Socket* Socket Information 24 volts ac. Protected by circuit breaker CB2. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volts ac contactor control circuit. 115 volts ac. Protected by circuit breaker CB1. C L N 115 VOLTS AC 115 VOLTS AC...

  • Page 25: Optional Gas Valve Operation And Shielding Gas Connection

    ‘ 5-7. Optional Gas Valve Operation And Shielding Gas Connection Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve. Cylinder Regulator/Flowmeter Install so face is vertical. Gas Hose Connection GAS IN Fitting has 5/8-18...

  • Page 26: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Front Panel Controls Power Switch tion. voltage is the same as normal welding amperage. Remote 14 Receptacle The fan motor is thermostatically When set towards maximum, short-circuit controlled and only runs when cooling is For remote control, make connections to Re- amperage is increased at low arc voltage to needed.

  • Page 27: Meter Functions

    6-2. Meter Functions The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Meter Reading While Welding Scratch 71.7 10.3 Start TIG Actual Volts (OCV) Preset Amps Actual Volts Actual Amps 10.3 Lift-Arc Trigger Hold TIG...

  • Page 28: Lift-Arc Trigger Hold Tig

    6-4. Lift-Arc Trigger Hold TIG TIG Electrode Workpiece Procedure requires: control Start sequence: • Touch tungsten electrode to workpiece at weld start point. • Momentarily depress output switch. • Slowly lift electrode. An arc will 1 − 2 form when electrode is lifted. “Touch”...

  • Page 29: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. 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 30: Voltmeter/Ammeter Help Displays

    7-3. Voltmeter/Ammeter Help Displays HE.L P−1 HE.L P−5 HE.L P−2 HE.L P−6 HE.L P−3 HE.L P−8 Indicates the left side of the unit has over- current limit. As the line voltage decreases, All directions are in reference to the front heated.
  • Page 31 Notes OM-234 816 Page 27...

  • Page 32: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-234 816 Page 28...
  • Page 33 219 484-C OM-234 816 Page 29...

  • Page 34: Section 9 − Parts List

    SECTION 9 − PARTS LIST Ref. 803 850-F Figure 9.1. Parts Assembly OM-234 816 Page 30...
  • Page 35 Item Dia. Part Mkgs. Description Quantity Figure 9.1. Parts Assembly ....216 034 Wrapper (Includes Insulators and Safety Labels) ....
  • Page 36 Item Dia. Part Mkgs. Description Quantity Figure 9.1. Parts Assembly (Continued) ....234 126 Nut, Conduit 1.000 Npt Knurled ........
  • Page 37 Item Dia. Part Mkgs. Description Quantity Figure 9.1. Parts Assembly (Continued) ....174 992 Knob, Pointer .840 Dia X .250 Id W/Spring Clip−.21 .
  • Page 38 Notes...

  • Page 39: Warranty

    Warranty Effective January 1, 2008 (Equipment with a serial number preface of LJ or newer) Induction Heating Coils and Blankets, Cables, and This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or Non-Electronic Controls warranties expressed or implied.
  • Page 40 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 Contact the Delivering Carrier for: File a claim for loss or damage during shipment.

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