Auto Continuum PDF

TM-273473A 2017−08
Eff w/Serial No. MG140540C
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)

Cutting and Gouging
Description
Arc Welding Power Source
Auto−Continuum
®
350 And 500

And Drive Assembly
Also Includes Auto−Continuum Drive

(TM−273476) Starting in Section 15
For product information, File: Advanced Manufacturing Systems

Owner’s Manual translations,
and more, visit
www.MillerWelds.com
INFORMATION ON OLDER UNITS
. This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com
. Eff. w/MG330505C, fuse dimensions and ratings were increased on power supply circuit board PC13 and feeder power circuit board PC14.
. Eff. w/MG480509C, water cooler option was added to Auto−Continuum 350 and 500.
. See the Miller Extranet for service memos that may aid in the repair of this product.
. This manual provides service and repair information for the Auto−Continuum 350 and 500 and Auto−Continuum Drive assembly. The Auto−Con-
tinuum Drive assembly information begins with Section 15.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-2. 350 Model Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-3. 500 Model Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-4. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-6. Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-3. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Remote 10 Wire Feeder Control Receptacle RC2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-5. Volt Sense Receptacle RC3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Peripheral Receptacle RC22 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-7. Devicenet Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-8. Supplementary Protector CB1, Communication Panel, And E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-9. Aux Power And CB2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-11. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 5 − RECOMMENDED SETUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-1. Welding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-2. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-3. Using Multiple Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-4. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs . . . . . . . . . . . . . . . . . 22
5-5. Earth Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-6. 30 Points Of Mechanics In MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-1. Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-2. User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-3. Description Of Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 7 − CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-1. Accessing Configuration Web Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-2. Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-3. Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-4. Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-5. Arc Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-6. Data Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7-7. Help Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 8 − AUTO-CONTINUUM 350 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 9 − AUTO-CONTINUUM 500 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TABLE OF CONTENTS
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10-1 . Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10-2. Measuring/Discharging Input Capacitor Voltage Before Working On Unit . . . . . . . . . . . . . . . . . . . . 41
10-3. Power Switch S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10-4 . Input Contactor And Input Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10-5 . Input Rectifier SR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10-6 . Input Rectifier SR1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10-7 . Capacitor Boards PC2 And PC3 − 350 And 500 Models (Use With Section 10-8) . . . . . . . . . . . . . 45
10-8 . Capacitor Board PC3 − 350 And 500 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10-9 . Boost And Inverter IGBTs (Use With Sections 10-10 and 10-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10-10. 350 Model IGBT Module Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10-11. 500 Model IGBT Module Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10-12. Output Diodes D1, D2, D3, D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-13. Power Supply Board PC13 Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-14. Wire Feeder Power Board PC14 Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10-15 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10-16 Arc Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10-17 Basic Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-18 Troubleshooting Circuit Diagram (Page 1 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-19 Troubleshooting Circuit Diagram (Page 2 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10-20 Input Board PC1 Testing Information (Use With Section 10-21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10-21 Input Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10-22 Arc Control Board PC4 Testing Information (Use With Section 10-23) . . . . . . . . . . . . . . . . . . . . . . . 62
10-23 Arc Control Board PC4 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10-24 Arc Control Board PC4 LED Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10-25 Feeder Power Board PC14 Testing Information (Use With Section 10-26) . . . . . . . . . . . . . . . . . . . 68
10-26 Feeder Power Board PC14 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10-27 Control Power Supply Board PC13 Testing Information (Use With Section 10-28) . . . . . . . . . . . . . 70
10-28 Control Power Supply Board PC13 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10-29 10 Pin Connector PC16 Testing Information (Use With Section 10-30 ) . . . . . . . . . . . . . . . . . . . . . 72
10-30 10 Pin Connector PC16 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10-31 LED Board PC18 Testing Information (Use With Section 10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10-32 LED Board PC18 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10-33 SBC PC19 Testing Information (Use With Section 10-34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-34 SBC PC19 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-35 AIM Board PC21 Testing Information (Use With Section10−36) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10-36 AIM Board PC21 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10-37 User Interface Board PC34 Testing Information (Use With Section 10−38) . . . . . . . . . . . . . . . . . . . 78
10-38 User Interface Board PC34 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10-39 User Interface Board PC34 Receptacle RC10 Switch Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10-40 Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10-41 Load Bank Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SECTION 11 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11-1 . Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11-2 . Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 12 − ERROR CODE TROUBLESHOOTING DESCRIPTION AND TABLES . . . . . . . . . . . . . . . . . 83
SECTION 13 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SECTION 14 − PARTS LIST FOR 350 AND 500 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage

OM-273473C - 2016−04, safety_stm 2015-09
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. Servicing Hazards
The symbols shown below are used throughout this manual STATIC (ESD) can damage PC boards.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Put on grounded wrist strap BEFORE handling
to avoid the hazard. boards or parts.
Only qualified persons should test, maintain, and repair this D Use proper static-proof bags and boxes to
unit. store, move, or ship PC boards.
During servicing, keep everybody, especially children, away.

FIRE OR EXPLOSION hazard.
ELECTRIC SHOCK can kill. D Do not place unit on, over, or near combustible
surfaces.
D Do not touch live electrical parts. D Do not service unit near flammables.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re-
ceptacle, or stop engine before servicing unless the procedure spe- FLYING METAL or DIRT can injure eyes.
cifically requires an energized unit.
D Wear safety glasses with side shields or face
D Insulate yourself from ground by standing or working on dry insulat-
shield during servicing.
ing mats big enough to prevent contact with the ground.
D Be careful not to short metal tools, parts, or
D Do not leave live unit unattended.
wires together during testing and servicing.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free. HOT PARTS can burn.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source. D Do not touch hot parts bare handed.
D Allow cooling period before working on
SIGNIFICANT DC VOLTAGE exists in inverter weld- equipment.
ing power sources AFTER removal of input power. D To handle hot parts, use proper tools and/or wear heavy, insu-
D Turn Off inverter, disconnect input power, and discharge input lated welding gloves and clothing to prevent burns.
capacitors according to instructions in Troubleshooting Section be-
fore touching any parts.
EXPLODING PARTS can injure.
ARC FLASH can kill.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
Arc flash is the rapid and violent release of energy that
occurs when electric current leaves its intended path D Always wear a face shield and long sleeves
and arcs to other conductors or to ground. Arc flash when servicing inverters.
can be caused by equipment failure (faulty insulation,
corrosion, dust) improper installation, human error (improper tool
placement), and other factors. Conductive vapors can sustain the
arc until over-current devices open the circuit. Individuals within
the arc flash boundary are at risk.
SHOCK HAZARD from testing.
D Do not work on energized equipment unless an assessment of D Turn Off welding power source and wire feeder
arc flash risk from the electrical supply circuit has been conducted or stop engine before making or changing me-
by a qualified person and you have been trained in safe work prac- ter lead connections.
tices by your employer. D Use at least one meter lead that has a self-
D Follow requirements in NFPA 70E for safe work practices and retaining spring clip such as an alligator clip.
Personal Protective Equipment (PPE). D Read instructions for test equipment.
Auto−Continuum 350 And 500 TM-273473 Page 1

FALLING EQUIPMENT can injure. OVERUSE can cause OVERHEATING.
D Use lifting eye to lift unit only, NOT running D Allow cooling period; follow rated duty cycle.
gear, gas cylinders, or any other accessories. D Reduce current or reduce duty cycle before
D Use equipment of adequate capacity to lift and starting to weld again.
support unit. D Do not block or filter airflow to unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit. H.F. RADIATION can cause interference.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu- D High-frequency (H.F.) can interfere with radio
ally lifting heavy parts or equipment. navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician prompt-
MOVING PARTS can injure. ly correct any interference problem resulting from the installa-
tion.
D Keep away from moving parts such as fans.
D If notified by the FCC about interference, stop using the
D Keep away from pinch points such as drive equipment at once.
rolls.
D Have the installation regularly checked and maintained.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance and D Keep high-frequency source doors and panels tightly shut, keep
troubleshooting as necessary. spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D Keep hands, hair, loose clothing, and tools
away from moving parts.
D Reinstall doors, panels, covers, or guards READ INSTRUCTIONS.
when maintenance is finished and before re-
connecting input power. D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
ELECTRIC AND MAGNETIC FIELDS (EMF) D Use only genuine replacement parts from the manufacturer.
can affect Implanted Medical Devices. D Read and follow all labels and the Technical Manual carefully be-
fore installing, operating, or servicing unit. Read the safety in-
D Wearers of Pacemakers and other Implanted
formation at the beginning of the manual and in each section.
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the D Perform installation, maintenance, and service according to the
device manufacturer. Technical Manual, industry standards, and national, state, and
local codes.
1-3. 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. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
1-4. EMF Information

Electric current flowing through any conductor causes localized electric 3. Do not coil or drape cables around your body.
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and 4. Keep head and trunk as far away from the equipment in the
induction heating operations) creates an EMF field around the welding welding circuit as possible.
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants 5. Connect work clamp to workpiece as close to the weld as
have to be taken. For example, restrict access for passers−by or con- possible.
duct individual risk assessment for welders. All welders should use the
6. Do not work next to, sit or lean on the welding power source.
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
1. Keep cables close together by twisting or taping them, or using a
cable cover. Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
2. Do not place your body between welding cables. Arrange cables If cleared by your doctor, then following the above procedures is recom-
to one side and away from the operator. mended.
TM-273473 Page 2 Auto−Continuum 350 And 500

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
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2017−04
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017−04
Disconnect input plug or power before working on machine.
Safe5 2017−04
Keep your head out of the fumes.
Safe6 2017−04
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Auto−Continuum 350 and 500 TM-273473 Page 3

Do not weld on drums or any closed containers.
Safe16 2017−04
Do not remove or paint over (cover) the label.
Safe20 2017−04
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2017−04
Do not discard product (where applicable) with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2017−04
TM-273473 Page 4 Auto−Continuum 350 and 500

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the

machine or welding.
Safe40 2012−05
V Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, AND check input capacitor
voltage, and be sure it is near 0 before touching any parts.
>5min V Safe43 2017−04
Notes

2-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A Amperage
Direct Current
(DC)
Alternating
Current (AC) V Voltage
Output Input Remote On
Off Positive Negative Voltage Input
Variable Protective Earth

Arc Force Constant Voltage
Inductance (Ground)
Gas Metal Arc

Increase Line Connection Arc Force
Welding (GMAW)
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2
Conventional
Load Voltage X Duty Cycle
Hz Hertz
IP Degree Of
Protection I2 Rated Welding
Current % Percent
S
Cold Jog (Inch) Suitable for Some
Away From Hazardous Single Phase Three Phase
Workpiece Locations
I1max I1eff
Cold Jog (Inch)
Rated Maximum Maximum Effective
Wire Feed Towards
Supply Current Supply Current
Workpiece
Purge By Gas Constant Current Trigger Hold Off Read Instructions
Locked I1 Primary Current Sequence Program
Process Wire Type Gas Type Time
Trigger Hold On Trigger Hold

Arc Control
Indicator Light Off Indicator Light

Use Sections 15 through 22 for Auto Continuum Drive
SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
3-2. 350 Model Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-10 and 4-11 for information on
connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Input Rated Voltage Amperage Max Amperes Input At Rated Load Output 60 Hz, Input Input
Power Welding Range Range Open Three-Phase kVA KW
Output CV Mode CC Mode Circuit
Voltage
DC 230 V 380 V 400 V 460 V 575 V
Three 350 A @ 10-44 V 20-400 A 75 36.7 21.8 20.8 18.8 14.6 14.4 13.8
Phase 34 V DC, (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0.8*) (0.17*)
100%
Duty
Cycle
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
3-3. 500 Model Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-10 and 4-11 for information on
connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).
Input Rated Voltage Amperage Max Amperes Input At Rated Load Output 60 Hz, Input Input
Power Welding Range Range Open Three-Phase kVA KW
Output CV Mode CC Mode Circuit
Voltage
DC 230 V 380 V 400 V 460 V 575 V
Three 500 A @ 10-44 V 20-600 A 75 58.7 34.9 33.2 28.9 23.3 23.1 21.9
Phase 40 V DC, (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0.8*) (0.17*)
100%
Duty
Cycle
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
Auto−Continuum 350 and 500 TM−273473 Page 7

3-4. Dimensions And Weight
Hole Layout Dimensions
A 17-33/64 in. (445 mm) *27-3/16 in.

**28−7/32 in. (691 mm)
B 17-3/8 in. (441 mm) (717 mm)
C 26-11/64 in. (665 mm) A

D
D 16-3/32 in. (409 mm)
E 2-9/32 in. (58 mm) E 24-57/64 in.

(632 mm)
F 15/32 in. (12 mm)
G
15/32 x 1 in.
G
(12 x 25mm)
Weight C B
350 Model:
130 lb (59.4 kg)
350 Model w/Aux Power: 18-3/16 in.
139 lb (63.5 kg) (462 mm)
500 Model: F
151 lb (69 kg)
500 Model w/Aux Power: *Height includes lifting eye
160 lb (73.1 kg) **Length includes E−Stop cover
Lifting Eye Weight Rating:
1000 lb (453 kg) Maximum 907657-tp1
3-5. Environmental Specifications

A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23S 2014−06
B. Temperature Specifications
Operating Temperature Range* Storage/Transportation Temperature Range
14 to 104 °F (-10 to 40°C) −4 to 131 °F (−20 to 55°C)

*Output is derated at temperatures above 104°F (40°C). Temp_2016- 07
3-6. Static Characteristics

The static (output) characteristics of the welding power source can be described as flat during the GMAW process and drooping during the CAC−A
process. Static characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors.
Contact the factory for specific information on the static characteristics of the welding power source.
TM−273473 Page 8 Auto−Continuum 350 and 500

3-7. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-
350 Model 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 At 350 Amperes 60% Duty Cycle At 400 Amperes
Continuous Welding 6 Minutes Welding 4 Minutes Resting
Overheating
0 A/V
15
OR
Minutes Reduce Duty Cycle
500 Model
100% Duty Cycle At 500 Amperes 50% Duty Cycle At 600 Amperes
Continuous Welding 5 Minutes Welding 5 Minutes Resting
0 A/V
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 − SA-268 499-A / 268 498-A

SECTION 4 − INSTALLATION
4-1. Selecting A Location
Movement
! Do not move or operate

unit where it could tip.
3
1
OR OR
Location And Airflow
4 ! Special installation may be required

where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
! Do not stack units. Beware of tipping.
1 Lifting Eye
18 in. 2 Lifting Forks
(460 mm) Use lifting eye or lifting forks to move unit.
If using lifting forks, extend forks beyond
opposite side of unit.
3 Hand Cart
Use cart or similar device to move unit.
4 Line Disconnect Device
Locate unit near correct input power supply.
18 in.
(460 mm)
Loc_continuum 2015-07

4-2. Weld Output Terminals And Selecting Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and 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%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 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 (3x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**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.
( ) = mm2 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. Connecting Weld Output Cables
! Turn off power before connecting to

Tools Needed: weld output tabs or receptacles.
3/4 in. (19 mm) for output ! Do not use worn, damaged, under-
terminal type connection sized, or repaired cables.
! Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
Ensure all connections are tight.
Tab Connection
. Do not place anything between weld

cable terminal and output tab. Make
sure that the surfaces of the weld cable
terminal and output tab are clean.
1 Negative (−) Output Terminal
2 Positive (+) Output Terminal
3 Correct Weld Cable Connection For
Single Feeder
2/0 And Larger Double Cables
5 Incorrect Weld Cable Connection
6 Weld Output Terminal Bolt
7 Nut
8 Weld Cable Terminal
9 Output Terminal
Remove supplied nut and bolt from weld
output terminal. Insert bolt through hole in
weld cable terminal and hole in weld output
Positive Negative terminal. Screw nut onto bolt until weld
cable terminal is tight against output termi-
2 1 nal. Torque to 45-55 ft lb (61-75 N·m).
Front View
3 5
6 7
9 8
8
6 9 8 7
2/0 and larger double cables
XX

4-4. Remote 10 Wire Feeder Control Receptacle RC2 Information
Socket Socket Information
A +50 Volts DC Common
A H
B +50 Volts DC Common
B I G
J F
C
D E
C Voltage Sense (Originates from Feeder Wire Drive)
D +50 Volts DC Power
E +50 Volts DC Power
F ENET Rx −
G ENET Tx −
H Drain
I ENET Tx +
J ENET Rx +
907 657-tp2
4-5. Volt Sense Receptacle RC3 Information
A Not Used
B Volt Sense Negative (Originates from Sense Lead at Work Piece)
C Not Used
D Not Used
907 657-tp2

4-6. Peripheral Receptacle RC22 Functions
Socket Ref. Com Socket Information
A Output common
A M
B L
B Closure when weld contac- A Digital output 1 (DO1)
N
C
P tor on
T K
D S J
E R C Not defined Digital output 2 (DO2)
F
G H
D Closure to signal when A Digital output 3 (DO3)
touched
E Not Used
F Circuit common for AIM Chassis ground

board
G Input common
H *Turn on Touch Sense with G Request to turn on Touch Sense (DI1)

+24 VDC
J Not defined Digital input 2 (DI2)
K Not defined Digital input 3 (DI3)
L Not Used
M Not Used
N +24 VDC output goes high F Touched hardware signal

when touched 14 ohm impedance
P Not Used
R Not Used
S Not Used
T Not Used
. * 24VDC is from an external supply. (User supplied)
4-7. Devicenet Receptacle
A Chassis ground.
C
D B +24 volts DC; available current is 1 ampere.
B
A E C +24 volts DC common.
D CAN H.
E CAN L.
Ref. 277971-A

4-8. Supplementary Protector CB1, Communication Panel, And E-Stop

1 Ethernet Receptacle
Used for connecting a computer di-
rectly to the power source to ac-
cess configuration web pages.
4 2 Ethernet Receptacle
2 Used for connecting a robot directly
to the power source.
5 3 Supplementary Protector CB1
CB1 protects the wirefeed motor
from overload. If CB1 opens, the
1 wire feeder does not work.
. Press button to reset breaker.

4 Wireless (WiFi) Antenna
Antenna for connecting to the inter-
net via (WiFi) wireless connection if
selected during configuration.
5 E-Stop Receptacle RC24
A short across the two sockets al-
3 lows unit to weld.
907 657-tp2
4-9. Aux Power And CB2 (Optional)

1 115 V AC Receptacle
2 Supplementary Protector CB2
CB2 protects 115 V AC receptacle.
. Press button to reset breaker.
Ref. 907641−TP1 / 907657-tp2

4-10. Electrical Service Guide Elec Serv 2014−01
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical 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 210.21, 630.11, and
630.12.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
350 Model 60 Hz Three Phase

Input Voltage (V) 230 380 400 460 575
Input Amperes (A) At Rated Output 34.1 20.4 19.2 16.7 13.3
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses 2 50 30 30 25 20
Normal Operating Fuses 3 70 40 35 30 25
Min Input Conductor Size In AWG 4 8 10 12 12 14
119 215 146 193 196
Max Recommended Input Conductor Length In Feet (Meters)
(36) (66) (44) (59) (60)
Min Grounding Conductor Size In AWG 4 8 10 12 12 14
500 Model 60 Hz Three Phase

Input Voltage (V) 230 380 400 460 575
Input Amperes (A) At Rated Output 58.7 34.9 33.2 28.9 23.3
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses 2 70 40 40 35 25
Normal Operating Fuses 3 90 50 50 45 35
Min Input Conductor Size In AWG 4 6 8 8 10 10
142 247 273 237 371
Max Recommended Input Conductor Length In Feet (Meters)
(43) (75) (83) (72) (113)
Min Grounding Conductor Size In AWG 4 8 10 10 10 10
Reference: 2014 National Electrical Code (NEC) (including article 630)

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” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps 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
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.

4-11. Connecting 3-Phase Input Power
3
3 L1 (U)
6 L2 (V)
5
8 L3 (W)
= GND/PE Earth Ground
10
4
4 3
L1
L2 6
Input Power Contactor Connections
9 L3
Side View Of Unit
Tools Needed:
3/8 in.
3/16 in.
input5 2013−04 / 274300-B / 259119-C

4-11. Connecting 3-Phase Input Power (Continued)
! Installation must meet all National and 1 Input Power Conductors (Customer 6 Input Conductors L1, L2, L3
Local Codes − have only qualified per- Supplied Cord) Connect input conductors L1, L2, and L3 to
sons make this installation. Select size and length of conductors using welding power source line terminals.
! Disconnect and lockout/tagout input Section 4-10. Conductors must comply with Reinstall top cover on welding power source.
power before connecting input national, state, and local electrical codes. If
applicable, use lugs of proper amperage Disconnect Device Input Power
conductors from unit. Follow estab-
capacity and correct hole size. Connections
lished procedures regarding the in-
stallation and removal of lockout/ Welding Power Source Input Power 7 Disconnect Device (switch shown in the
tagout devices. Connections OFF position)
! Make input power connections to the 2 Strain Relief Kit 274 563 Supplied With 8 Disconnect Device Grounding Terminal
welding power source first. Machine 9 Disconnect Device Line Terminals
! Always connect green or green/yellow Install strain relief of proper size for unit and Connect green or green/yellow grounding
conductor to supply grounding input conductors. Route conductors (cord) conductor to disconnect device grounding ter-
terminal first, and never to a line through strain relief. Tighten strain relief. minal first.
terminal. 3 Welding Power Source Grounding Connect input conductors L1, L2, and L3 to
NOTICE − The Auto-Line circuitry in this unit Terminal disconnect device line terminals.
automatically adapts the power source to the
4 Green Or Green/Yellow Grounding 10 Over-Current Protection
primary voltage being applied. Check input
Conductor Select type and size of over-current protec-
voltage available at site. This unit can be con-
nected to any 3-phase input power between Route green or green/yellow grounding con- tion using Section 4-10 (fused disconnect
230 and 575 VAC without removing cover to ductor through current transducer and con- switch shown).
relink the power source. nect to welding power source grounding Close and secure door on disconnect device.
See rating label on unit and check input volt- terminal first.. Follow established lockout/tagout procedures
age available at site. 5 Welding Power Source Line Terminals to put unit in service.
Input5 2013−04
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

SECTION 5 − RECOMMENDED SETUP PROCEDURES
5-1. Welding Circuit

. Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics.
1 Welding Power Source

. Appearance of actual unit may differ from that shown. 2 Electrode Cable
1 3 Feeder Cable
Standard Welding Circuit 4 Work Cable
6 5 Voltage Sensing Lead
ECL 6 Robot
7 Workpiece
3
In pulse welding applications using
2 inverter power sources, cable
resistance can result in less than
satisfactory performance. In most
cases, a welding circuit length of 50 ft
(15 m) or less will provide satisfactory
4 performance with a standard welding
Gun circuit connection.
Travel
The length of a welding circuit is
5 determined as follows:
7
Welding Circuit = Electrode Cable
Length (ECL) + Work Cable Length
WCL
(WCL) + Workpiece Length (WL)
See Section 4-2 for weld cable size.
Variations in welding processes and
welding circuit resistance can affect
apparent voltage at the welding arc.
WL Voltage sensing can improve welding
performance by providing accurate
Current Flow Path feedback to the welding power source.
It is important to connect the voltage
1 sensing lead as near to the weld as
Large Weld Structure possible, but not in the return current
path.
3
6
2
ECL
4
4
5
7
WCL
WL
250 489-B
Current Flow Path

5-2. Arranging Welding Cables To Reduce Welding Circuit Inductance
. Appearance of actual unit may differ from that shown. 1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable
Bad 1 5 Voltage Sensing Lead
6 Robot
6 7 Workpiece
2 3 The arrangement of the cables has an
effect that is significant to the welding
properties. As an example, Accupulse
and RMD welding processes can
produce high welding circuit inductance
depending on cable length and
arrangement. This can result in limited
current rise during droplet transfer into
the welding puddle.
5
The Vsense option can be turned On or
Off in the Setup menu or by using the
4 web pages. The electrode sense lead is
contained in the feeder control cable
and compensates for voltage drop in all
semi-automatic processes when the
Vsense option is On . The work sense
7 lead connects to the Axcess welding
power source 4-pin connector located
above the negative output terminal. This
work sense lead compensates for work
cable voltage drop when connected to
Better 1 the welding power source when the
Vsense option is On.
Do not coil excess cables. Use cables
that are the appropriate length for the
6 application. Whenever using long weld
cables [longer than 50 ft (15 m)] try to
arrange positive and negative weld
cables together to reduce the magnetic
field surrounding the cables. Avoid
2 coupling the feeder and work sense
3 leads with the weld cables.
Best 1
2
3
4
5
7 250 503-B

5-3. Using Multiple Welding Power Sources
. Appearance of actual unit may differ from that shown.
1
1
2
2
4
5 4
5
6
Gun
Travel
Current Flow Path
250 504-B
1 Welding Power Source possible, but not in the return current path. Arc blow occurs primarily during the
2 Electrode Cable welding of steel or ferromagnetic metals.
Connect voltage sensing lead at the end of
the weld joint. Weld current will take the path of least
3 Feeder Cable resistance, but not always the most direct
4 Work Cable The direction of the welding path should be path through the workpiece to the work
away from the work cable connections. lead connection. The most intense magnet
5 Voltage Sensing Lead
Connect work clamp at the beginning of the force will be around the arc due to a
6 Robot difference in resistance for the magnetic
weld joint.
7 Workpiece path in the base metal. The work clamp
Each welding gun should have its own connection is important and should be
Each welding power source should have a source of shielding gas. Use a separate placed at the starting point of a weld. It is
separate work cable connection to the shielding gas regulator and shielding gas recommended to have as short of an arc as
workpiece. Do not stack or join work connection for each welding gun. possible so that there is less of an arc for
cables together at the workpiece. This is
Arc blow is the deflection of a welding arc the magnetic forces to control. Conditions
very important for pulse welding applica-
from its normal path due to magnetic affecting the magnetic force acting on the
tions.
forces. It will adversely affect the arc vary so widely that the reference here
It is important to connect the voltage appearance of a weld, cause excessive is only about cabling connections and arc
sensing lead as near to the weld as spatter, and impair the quality of a weld. preferences.

5-4. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs
A. Bad Setup
3
2
4 5
2
4
3
6
Current Flow Path
250 512-B
1 Welding Power Source 7 Workpiece across the workpiece will not be measured
2 Electrode Cable correctly for the voltage feedback signal.
This arrangement is a bad setup due to Voltage feedback to the welding power
3 Feeder Cable
sensing leads being directly in the current sources will not be correct at either sense
4 Work Cable flow path of the welding arc. Interaction lead and result in poor arc starts and arc
5 Voltage Sensing Lead between welding circuits will affect voltage quality.
6 Robot drop in the workpiece. The voltage drop

B. Better Setup
3
2 1
6 5
7 2
6 5
Current Flow Path
250 513-B
1 Welding Power Source 6 Robot the welding power sources. The most
2 Electrode Cable accurate voltage sensing may not be
7 Workpiece achieved due to voltage drops in the
3 Feeder Cable
workpiece. This may require
4 Work Cable This arrangement is a better setup for compensation in the welding parameters.
5 Voltage Sensing Lead supporting separate voltage feedback to

C. Best Setup
3
2 1
5
6 7 4
2
5
4
6
Current Flow Path
250 515-B
1 Welding Power Source 5 Voltage Sensing Lead This arrangement is the best setup for
2 Electrode Cable proper voltage sensing at the workpiece.
6 Robot Voltage feedback to the welding power
3 Feeder Cable sources will more accurate and result in
4 Work Cable 7 Workpiece reliable arc starts and better arc quality.

5-5. Earth Grounding

When using a robot or any programmable controls, it is necessary to connect equipment to a good earth ground. Grounding helps eliminate electrically
generated noise from corrupting processing data or the potential damage to sensitive electrical components. Electrical noise is an issue anytime high
frequency TIG equipment or inverter type power supplies are used in the area. A method for checking for a good earth ground is shown below. Also, be
sure to a good connection to the earth ground.
110 Volts AC
100W Light Bulb
Neutral
V
1 Volt 1 W
Earth Ground
Being Measured
Measuring Facility (Earth) Ground Resistance
The resistance of an earth ground can be measured using a 100W light bulb, an ac voltmeter and a 110 volts AC electrical drop. As shown in the circuit,
the 110 volts AC (hot) supply and the 100W light bulb approximate a 1 ampere current source when the light bulb circuit is completed by connecting to
the earth ground. The AC voltmeter, referenced to the AC neutral line, can then be used to measure the voltage rise due to the 1 ampere current source
through earth ground. Each volt of rise on the earth ground represents 1 ohm of resistance. A resistance of less than 10 ohms at the earth ground should
be adequate.

Input Power
IMPORTANT: DO NOT mount anything to robot control cabinet. Supply Line
Line Disconnect Switch Box

For Input Power To Fixture Existing
Positioning And Peripheral Input Power
Equipment Supply Ground
TM−273473 Page 26
Make Separate Equipment
Earth Ground Using A Minimum
Of No. 3 Gauge Copper Braided
Cable That Provides A Resistance
Value Less Than 100 Ohms Between
The Component Connection And
The Ground Wire
Line
Input Power Disconnect Input Power
Supply Line Switch Box Supply Line

Insulating
Plate
Under Robot
Make Ground
Lead 5 ft. (1.5 m) Line
To 10 ft. (3 m) Longer Disconnect
Existing And Coil It Inside
Input Power Switch Box
Robot Control
Supply
Ground Existing
Work Weld Input Power
Cable Supply Ground
Worktable
Robot
15 ft. Control
Welding (4.5 m) If Using
Power Conduit,
Source Isolate It
From Robot
Control
Cabinet
10 ft. (3 m)
Minimum 5 ft. Insulating Liner
5 ft. (1.5 m) Strips Under Both
(1.5 m) Support Channels
Use Proper Size Input And Ground Customer Supplied Driven Ground Rod Use Proper Size Input And Ground
Conductors For The Input Power Or Separate Earth Ground Connection Conductors For The Input Power
Supply Line Voltage Less Than 100 Ohms To Building Ground Supply Line Voltage
Figure 9-1. Earth Ground Connections To Stationary Robot System Components SB-136 221-A
Auto−Continuum 350 and 500

5-6. 30 Points Of Mechanics In MIG Welding 30 Pts MIG − 2014-09
Primary Power
S Check primary power connection at line disconnect switch or receptacle and/or cord plug.
S Check primary power connection at welding power source.
Secondary Power
S Check secondary weld output connections at welding power source.
S Inspect condition and routing of positive weld cable to wire drive motor.
S Check connection of positive weld cable to wire drive motor.
S Inspect condition and routing of negative weld cable to fixture.
S Check connection of negative weld cable to fixture.
S Inspect condition of any rotary grounds, grounding shoes or other auxiliary grounds.
S Check installation, routing and condition of welding gun.
Shielding Gas
S Check gas hose connection to shielding gas supply regulator.
S Check shielding gas flow rate.
S Check gas hose routing.
S Check gas hose connection at wire drive housing.
S Check gun connection at wire drive and be sure O−rings seal at drive housing.
S Check condition of gas diffuser.
S Check condition of nozzle.
S Check O-ring for proper sealing at nozzle.
Welding Wire
S Inspect condition of de-reeler. Check for wear at quick-connect coupling and replace if necessary.
S Check placement of payoff pack or drum for smooth feed path.
S Inspect condition and routing of input conduit.
S Check installation of quick-connect coupling at rear of wire drive so that it does not contact drive rolls. Check for wear and replace if necessary.
S Check drive rolls and replace if worn.
S Check for drive roll tension setting.
S Check intermediate guide for proper size to match wire size and replace if worn.
S Check for proper length of liner at both ends and be sure it is cut without burrs.
S Check liner for proper size to match wire size.
S Check liner for wear and clean out to prevent plugging.
S Check contact tip for proper size to match wire size.
S Check contact tip for wear and change at regular intervals.
S Check contact tip for a tight fit and secure installation at gun.

SECTION 6 − OPERATION
6-1. Operator Controls
1 Power Switch
Turns unit On or Off.
2 Power On LED
Power LED illuminates when unit is
energized.
3 Output On LED
Output LED illuminates when weld
output is energized.
4 Error LED
On Solid−
Unit has overheated and weld out-
put has been disabled. Allow unit to
cool to operating temperature. Er-
ror LED will turn off and welding
may resume.
Blinking−
A system error has occurred. Use
the User Interface to determine the
1 source of the error as well as possi-
ble solutions. Follow on-screen in-
structions to clear the error. When
the error has been cleared the Error
LED will stop blinking and welding
may resume.
. After turning unit off, wait until

Power ON LED is off before
turning unit back on. Cycling
power too quickly can cause
software issues on power up.
Ref. 257195-G

6-2. User Interface
1 10 13 12 18 14 15 16 8
17
11
20
7
6
19
Ref. 266 061-B

5

6-3. Description Of Front Panel Controls (See Section 6-2)
1 Memory Display button. Press the button to select options 13 Voltage Indicator
The Memory display shows the active weld available in the LCD display
LED illuminates to show that the voltage
program. The range is from 0001 to 9999. 7 Values/Parameters LCD Display function is active.
2 Memory/Variable Adjustment Knob This display shows all values and parame- 14 Synergic Mode Active Indicator
ters that have been selected using the Soft
Use this knob to select a program number LED illuminates to show that a synergic
Key buttons and the Scroll knob and Save/
or increase/decrease the variable shown in weld process is active.
Select button.
the Memory display.
8 Amperage/Wire Feed Speed Display 15 Amperage Indicator
3 Arc Control Button
This display shows amperage, or wire feed LED illuminates to show that a SMAW,
The Arc Control button is process depen- speed depending on the process selected. GMAW or CAG process is selected. Values
dent. It allows user to change the variable appear on the Voltage/Arc Length/Induc-
that appears on the Values/Parameters dis- 9 Amperage/Wire Feed Speed/Material
Thickness Adjustment Knob tance/Arc Adjust/RMD display.
play, such as inductance, DIG, RMD (ball
size) or trim. The range can be +/− depend- Use this knob to increase/decrease amper- 16 Wire Feed Speed Indicator
ing on the process. age, wire feed speed, or material thickness LED illuminates to show that a GMAW or
depending on the process selection. These GMAW-P weld process is selected. Values
4 Memory 1-8 Buttons And LEDs
values appear on the Amperage/Wire Feed appear on the Amperage/Wire Feed Speed/
Use these buttons to select a stored Speed/Material Thickness display. Material Thickness display.
program from the weld program library data.
10 Voltage/Arc Length/Inductance/Arc 17 Material Thickness Indicator
The LED will indicate which program is
Adjust/RMD Display
selected and active. This feature will be functional in a later soft-
The Variables/Parameters display will This display shows voltage, arc length, in-
ware release.
show weld program library summary data ductance, arc adjust or RMD depending on
for the selected program. the process selected. 18 Output ON Indicator
5 Soft Key Buttons 11 Voltage/Arc Control Adjustment Knob LED illuminates to show that open circuit
Use this knob to increase/decrease voltage voltage is present at the weld output termi-
Use these buttons to navigate the menus nals.
appearing in the LCD display or arc length depending on the process se-
lection. These values appear on the 19 USB Port
6 Scroll Knob And Select/Save Button Voltage/Arc Length/Inductance/Arc Adjust/
Rotate this knob to scroll available options RMD display. Use this port for all USB related functions
or increase/decrease the variable shown in 12 Arc Length Indicator 20 Parameter Lock Indicator
the LCD display.
LED illuminates to show that arc length LED illuminates to show weld parameters
Pressing this knob acts as a Select/Save function is active. are locked and active.
* Disabled or not available.

SECTION 7 − CONFIGURATION
7-1. Accessing Configuration Web Pages
To access the power source configuration webpages, connect a PC directly to the jack on the communication panel with a CAT5 or CAT6 Ethernet
cable.
Enter the default IP address, 169.254.0.2, into a web browser and the welder configuration web pages will open to the Home screen.
7-2. Home Screen
9 7
1 Navigation Bar Displays the program number, process, wire 7 Last Weld
Select Home, Setup, Arc Management, Data size and alloy, and gas. Edit button allows Displays the voltage and amperage used dur-
Management, or Help screens. these parameters to be changed. ing the last weld made.
2 Information Bar 5 Weld Outputs (Live)
8 Productivity
Displays general information on power Displays the weld output conditions of the
source, location, asset number, serial num- power source and feeder in real time. Displays arc time, the amount of wire used,
ber, and display language. and the amount of wire remaining.
6 Commands
3 Power Source Information Displays current user changeable com- 9 Active Error
Displays power source information. Edit but- mands. Depending on the weld process being Displays any active error messages. View
ton allows these parameters to be changed. used these commands will vary. Edit button Error Log button will display a list of previous
4 Active Program allows parameters to be changed. errors and the time at which they occurred.

7-3. Setup Screen
2
1
3
4 5
7 8
10 11
12
13
14
1 Information Bar 6 Data Connections 11 Wire Spool

Displays information on power source, loca- Displays which data connections are enabled. Displays wire type, spool size, and amount of
tion, asset number, serial number, and lan- 7 Region wire remaining on the spool. Edit button allows
guage. wire information to be changed or reset.
Displays current region. Edit button allows re-
2 Purge Time gion to be changed. 12 Weld Cable Setup
Displays the length of time gas will flow when 8 Status Displays length and diameter of positive and
the purge button is pressed. Edit button allows negative weld leads, torch, and voltage feed-
time length to be changed. Displays the status of various system selec- back (VFB) method that are selected. Edit but-
tions: English vs Metric display values, Slope ton allows these parameters to be changed.
3 Enabled Errors Adjustment enable/disable, Synergic MIG En-
Displays which system errors are enabled. able/Disable, CE vs English weld library avail- 13 Robot Options
Click Edit to enable or disable system errors. ability, Arc length command scaling. Displays current robot connectivity options.
4 Jog Speed 9 WiFi Settings Edit button allows robot options to be
changed.
Displays the min and max jog speeds in inch- Edit button allows changes to WiFi settings
es per minute (IPM). Edit button allows min 14 Dry Run
10 Auto Thread
and max jog speed settings to be changed. Allows an automated weld cell to cycle without
Displays the Load Rate in inches per minute
5 Ethernet Settings striking an arc by simulating the arc detected
(IPM) and Torch Length (Inches) to determine
signal back to the weld cell
Edit button allows changes to connectivity the length of time for Auto Threading. Edit but-
settings. ton allows these parameters to be changed.
7-4. Setup Screen

2
1
3
4 5
7 8
11
10
12
13
14
15
1 Information Bar Displays which data connections are enabled Displays wire type, spool size, and amount of
Displays general information on welding pow- or disabled. wire remaining on the spool. Edit button allows
er source, location, asset number, serial num- 7 Region wire information to be changed or reset.
ber, and display language. Displays current region. Edit button allows re- 12 Weld Cable Setup
2 Purge Time gion to be changed. Displays length and diameter of positive and
Displays the length of time gas will flow when 8 Status negative weld leads, torch, and voltage feed-
the purge button is pressed. Edit button allows Displays the status of various system selec- back (VFB) method that are selected. Edit but-
time length to be changed. tions: English vs. Metric display values, Slope ton allows these parameters to be changed.
3 Enabled Errors Adjustment enable/disable, Synergic MIG en- 13 Robot Options
Displays which system errors are enabled. able/disable, CE/English weld library avail-
ability, Arc length command scaling Displays current robot connectivity options.
Click Edit to enable or disable system errors.
Edit button allows robot options to be
4 Jog Speed 9 WiFi Settings changed.
Displays the minimum and maximum Jog Edit button allows user to change WiFi
14 Dry Run
speeds in inches per minute (IPM). Edit button Settings.
allows minimum and maximum jog speed set- 10 Auto Thread Allows an automated weld cell to cycle without
ting to be changed for forward and reverse jog. striking an arc by simulating the arc detected
Displays the Load Rate in inches per minute
5 Ethernet Settings signal back to the weld cell
(IPM) and Torch Length (Inches) to determine
Edit button allows user to change connectivity the length of time for Auto Threading. Edit but- 15 Auto Calibration
settings. ton allows these parameters to be changed. Edit button will display last auto calibration,
6 Data Connections 11 Wire Spool give live feedback of auto calibration values.

7-5. Arc Management Screen
1 2 3
5
4
6
1 Active Program Edit button allows changes to these parame- 6 Weld Processes
Displays the program number, process, wire ters. Parameter limits are also set through this Displays available weld processes. Edit but-
size and alloy, and gas. Edit button allows menu. ton allows processes to be enabled or dis-
these parameters to be changed. 4 Lock Status abled.
2 Commands 7 Program Naming
Displays the current status of system locks.
Displays current user changeable commands. Edit button allows the lock configuration to be Edit button allows user to enter a short person-
Depending on the weld process being used changed. alized name for a weld program and a longer
these commands will vary. Edit button allows description of what the program is for. Both
parameters to be changed. 5 Program Enable
fields must have data entered. The short name
3 Weld Sequence Edit button allows user to select which pro- will then be viewable on the LCD screen on the
Displays active weld sequence parameters. grams are available for use. User Interface of the Continuum.

7-6. Data Management Screen
1 2 3
5
4
6
1 Productivity Factory Reset button will take user to a Facto- View button displays a list of the entries made
ry Reset screen. Read and follow all instruc- to the system log and the time at which they
Displays arc time and wire used in inches and tions on Factory Reset screen to perform a occurred.
pounds. Click Reset Data to reset productivity Factory Reset. 6 Wire Usage
data.
4 Error Log Displays the amount of wire used, the amount
remaining, and the date the spool was started.
2 Lifetime Information Displays the last error experienced by the Click Reset Data when starting a new spool.
system.
Displays total arc time, arc starts, and wire 7 Secondary Log
used over lifetime of unit. View button displays a list of previous errors View button displays a list of secondary com-
and the time at which they occurred. pensation tests that were run, listing Pass/Fail
3 Software Information status, date/time test was run, torch resis-
5 System Log
tance, torch voltage, weld cable resistance,
Displays the software revision. Displays the last entry into the system log. weld cable voltage, and weld cable current.
7-7. Help Screen
. The Help Screen contains

1 3 three drop down menus
2 which contain the features
on the Setup, Arc Manage-
ment and Data Management
screens.
1 Setup Information
Drop−Down Menu
2 Arc Management
Drop−Down Menu
3 Data Management
Drop−Down Menu

SECTION 8 − AUTO-CONTINUUM 350 THEORY OF

OPERATION
1 Power Switch S1
Provides on/off control of power
source. Controls input power to 1
precharge unit.
Power Switch
2 Input Contactor W1 S1
Connects input power to rectifier 4
circuit. W1 3
Three−Phase Inductor *24
3 Input Board PC1 Line Input Input BD L1 Inductor
Power PC1
Provides electrical connection for input L6
Rectifier
inductors L1−L2 and input rectifier. Pro- Module 4
vides current sense signals to Inductor
28 L2
pre-regulator control.
Hall Device Current *23
4 Input Inductors L1−L2 Power Cord HD2 Sense Aux Power
Ground Lead Signals
Smooth current flow from rectifier cir- Board
cuit to pre-regulator circuit. PC20
5 Upper Capacitor Board PC2
920VDC
Provides electrical connection for up-
per bus capacitors, pre-regulator 5
power modules, and inverter power
Upper Capacitor Board PC2
modules. Provides upper bus voltage
feedback signal to pre-regulator
Pre-Regulator Inverter
control. Power Power
6 Lower Capacitor Board PC3 Modules Modules
Provides electrical connection for low-
er bus capacitors, pre-regulator power
modules, and inverter power modules.
Provides lower bus voltage feedback
920VDC
signal to pre-regulator control.
7 Current Transformers CT1 10 11
Provide current feedback from primary Control Fan Motors
Power 115VAC FM1,FM2
windings of main transformer T1 to
control board PC4. Supply
Board
8 Main Transformers T1 2
PC13
Input
Step down bus voltage for weld output. Contactor
9 Output Diodes D1−D2 +15V, +5V, W1
Upper Bus −15V, +15V,
Rectify outputs of main transformer T1 Voltage −24V −15V
to provide DC weld power. Feedback 12
10 Control Power Supply PC13 Fan
Signal
Provides control voltages for internal
power supply control circuits. Derives
power from 920 VDC bus. Also pro- Pre-Regulator
vides 115 VAC fan control to drive fan Control
motors FM1, FM2.
11 Fan Motors FM1, FM2
Arc Control Board PC4
Cool internal components.
12 Arc Control Board PC4 Lower Bus
Voltage
Controls pre-regulator circuit to provide Feedback
920 VDC bus by providing PWM con-
trol signals to pre-regulator power
modules. Controls inverter circuit by
providing PWM control signals to in-
verter power modules. Provides weld 6
process control by monitoring feed-
back signals. Communicates over
Ethernet with single board computer Pre-Regulator Inverter
(SBC) board PC19 directly, and wire Power Power
feeder through 10 pin remote filter Modules Modules
board PC16.
13 Power Supply Board PC14 Lower Capacitor Board PC3
Provides 50 VDC power for wire feeder
and other remote devices. Derives
power from 920 VDC bus.

14 LED Board PC18

*25 *26
Provides LED indicators on front panel
Supplementary 115 VAC of power source.
Protector Receptacle
CB2 RC15 15 SBC Board PC19
20 Single Board Computer (SBC) Board
115 VAC communicates over Ethernet with weld
Positive (+) Electrode process control circuit to provide weld
Weld Output data and control.
Terminal
16 10 Pin Remote Filter Board PC16
18 19 20
Provides 50 VDC power and Ethernet
Hall Output Negative (−) communication with wire feeder, user
Device Inductor Weld Output Work interface, or other remote devices.
HD1 L5 Terminal Provides remote voltage sense feed-
back from wire feeder to Arc Control
board PC4.
17 Thermistors RT1, RT2, RT3
Detect heating conditions in lower pri-
29
mary heat sink (RT1), upper primary
Automation heat sink (RT2), and output heat sink
Module (RT3).
22 9 PC21
8 18 Hall Device HD1
Series Main Output
Capacitor Provides weld current feedback signal
Transformer Diodes
C6 D1,D2 to Arc Control board PC4.
T1
19 Output Inductor L5
920VDC Smoothes output weld current.
50VDC
50VDC 27 20 Weld Output Studs Positive (+)
13 and Negative (−)
User
Feeder Power 50VDC 21 Supplementary Protector CB1
Interface
Supply PC34
Board Provides overload protection for
21 50 VDC power.
PC14
Supplementary Connection
Protector to Wire 22 Series Capacitor C6
CB1 Feeder Provides protection against T1 satura-
14 15 Ethernet tion. Saturation occurs when the volt-
16 age across the transformer is not bal-
LED
Board SBC Board 10 Pin Remote anced. The unbalanced voltage ap-
PC18 PC19 Filter Board
50VDC pears as a DC offset voltage across
PC16
the transformer and can cause T1 pri-
Ethernet Ethernet mary overcurrent. The capacitor pro-
Ethernet tects against this condition by blocking
the DC offset.
Current
Feedback *23 Aux Power Board PC20
Provides 115 VAC power for RC15
Inverter Weld Process Voltage receptacle.
Control Control Feedback
*24 Inductor L6
Voltage
Feedback Smooths the AC output from Aux Pow-
er Board PC20.
17 *25 Supplementary Protector CB2
Thermistors Provides overload protection for 115
RT1,RT2,RT3 Connection VAC power.
To Cooler *26 Receptacle RC15
T1 Primary Provides 115 VAC auxiliary power.
Current
Feedback 27 User Interface PC 34
7
Displays wire speed, arc voltage, help
Current messages, and other welding
Transformer parameters.
CT1
28 Hall Device HD2
AC, DC or Ethernet Control Circuits Provides feedback when current is de-
tected on ground lead of power cable.
3φ Power 29 Automation Board PC21

Provides an interface for I/O signals,
voltage feedback and digital signals
from the robot controller.
Weld Current Circuit
* For Aux. Power Option

SECTION 9 − AUTO-CONTINUUM 500 THEORY OF

OPERATION
1 Power Switch S1
Provides on/off control of power
source. Controls input power to 1
precharge unit.
Power Switch
2 Input Contactor W1 S1
Connects input power to rectifier cir- 4
cuit. W1 3
Three−Phase Inductors *23
3 Input Board PC1 Line Input Input BD L1,L2 Inductor
Power PC1
Provides electrical connection for input L6
Rectifier
inductors L1−L4 and input rectifier. Pro- Module 4
vides current sense signals to 27 Inductors
pre-regulator control. L3,L4
Hall Device Current *22
4 Input Inductors L1−L4 Power Cord HD2 Sense
Ground Lead Aux Power
Smooth current flow from rectifier cir- Signals Board
cuit to pre-regulator circuit. PC20
920VDC
Provides electrical connection for up-
per bus capacitors, pre-regulator 5
power modules, and inverter power
Upper Capacitor Board PC2
modules. Provides upper bus voltage
feedback signal to pre-regulator con-
Pre-Regulator Inverter
trol. Power Power
6 Lower Capacitor Board PC3 Modules Modules
Provides electrical connection for low-
er bus capacitors, pre-regulator power
modules, and inverter power modules.
Provides lower bus voltage feedback
920VDC
signal to pre-regulator control.
7 Current Transformers CT1, CT2 10 11
Provide current feedback from primary Control Fan Motors
Power 115VAC FM1,FM2
windings of main transformers (T1, T2)
to control board PC4. Supply
Board
8 Main Transformers T1, T2 2
PC13
Input
Step down bus voltage for weld output. Cont actor
9 Output Diodes D1−D4 +15V, +5V, W1
Upper Bus −15V, +15V,
Rectify outputs of main transformers Voltage −24V −15V
T1, T2 to provide DC weld power. Feedback 12
10 Control Power Supply PC13 Fan
Signal
Provides control voltages for internal
power supply control circuits. Derives
power from 920 VDC bus. Also pro- Pre-Regulator
vides 115 VAC fan control to drive fan Control
motors FM1, FM2.
11 Fan Motors FM1, FM2
Arc Control Board PC4
Cool internal components.
12 PWM Control Board PC4 Lower Bus
Voltage
Controls pre-regulator circuit to provide Feedback
920 VDC bus by providing PWM con-
trol signals to pre-regulator power
modules. Controls inverter circuit by
providing PWM control signals to in-
verter power modules. Provides weld 6
process control by monitoring feed-
back signals. Communicates over
Ethernet with single board computer Pre-Regulator Inverter
(SBC) board PC19 directly, and wire Power Power
feeder through 10 pin remote filter Modules Modules
board PC16.
13 Power Supply Board PC14 Lower Capacitor Board PC3
Provides 50 VDC power for wire feeder
and other remote devices. Derives
power from 920 VDC bus.

*24 14 LED Board PC18

*25
Supplementary Provides LED indicators on front panel
115 VAC
Protector Receptacle of power source.
CB2 RC15 15 SBC Board PC19
20 Single Board Computer (SBC) Board
115 VAC communicates over Ethernet with weld
Positive (+) Electrode process control circuit to provide weld
Weld Output
Terminal data and control.
16 10 Pin Remote Filter Board PC16
18 19 20
Provides 50 VDC power and Ethernet
Hall Output Negative (−) communication with wire feeder, user
Device Inductor Weld Output Work
HD1 Terminal interface, or other remote devices.
L5
Provides remote voltage sense feed-
back from wire feeder to PWM control
board PC4.
17 Thermistors RT1, RT2, RT3
28 Detect heating conditions in lower pri-
Automation mary heat sink (RT1), upper primary
Module heat sink (RT2), and output heat sink
7 PC21 (RT3).
8 9
Current 18 Hall Device HD1
Main Output
Transformer Diodes Provides weld current feedback signal
CT1 Transformer
T1 D1,D2 to PWM control board PC4.
19 Output Inductor L5
920VDC Smoothes output weld current.
50VDC
50VDC 26 20 Weld Output Studs Positive (+)
13 User and Negative (−)
Feeder Power 50VDC Interface 21 Supplementary Protector CB1
Supply PC34
Board 21 Provides overload protection for
PC14 50 VDC power.
T1 Primary Supplementary Connection
Current Protector to Wire *22 Aux Power Board PC20
Feedback CB1 Feeder Provides 115 VAC power for RC15
14 15 Ethernet
16 receptacle.
LED
Board SBC Board 10 Pin Remote *23 Inductor L6
PC18 PC 19 Filter Board
50VDC Smooths the AC output from Aux Pow-
PC16
er Board PC20.
Ethernet Ethernet
*24 Supplementary Protector CB2
Ethernet
Provides overload protection for 115
Current VAC power.
Feedback
*25 Receptacle RC15
Inverter Weld Process Voltage Provides 115 VAC auxiliary power.
Control Control Feedback
26 User Interface PC34
Voltage
Feedback Displays wire speed, arc voltage, help
messages, and other welding
parameters.
17
27 Hall Device HD2
Thermistors Connection
T2 Primary RT1,RT2,RT3 Provides feedback when current is de-
Current To Cooler tected on ground lead of power cable.
Feedback 28 Automation Board PC21
Provides an interface for I/O signals,
7 voltage feedback and digital signals
8 9 from the robot controller.
Current Output
Transformer Main * For Aux. Power Option
Transformer Diodes
CT2 D3,D4
T2
AC, DC or Ethernet Control Circuits
3φ Power
Weld Current Circuit

SECTION 10 − TROUBLESHOOTING
10-1. Checking Unit Before Applying Power
NOTICE−See Section 10-18 for test points and
values and Section 14 for parts location.
NOTICE−Use MILLER Testing Booklet (Part
No. 150853) when servicing this unit.
NOTICE−See the Miller Extranet for service
memos that may aid in the repair of this
product.
! Discharge input capacitors according to Section 10-2 and be sure voltage is near zero before touching any parts.
! Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.
! Although some parts are briefly checked here, more complete tests may be needed later for these parts. This procedure is sim-
ply to get a basic okay to power up unit.
NOTICE−The pre-power checks should be done if any of the following conditions exist:
the unit is completely inoperative;
the symptoms are unknown;
visual damage is found on any circuit card assemblies, IGBT modules, input rectifier, or output diodes;
there is no output or limited output.
Notes

PRE-POWER CHECKS
10-2. Measuring/Discharging Input Capacitor Voltage Before Working On Unit
Tools Needed: ! Turn Off welding power
source, and disconnect
input power.
3/8 in ! Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
350 Models voltage as shown to be sure
the input capacitors have
1 2 discharged before working
on unit.
3 PM3−E2 Remove side panels and top cover.
4 PM3−C1 1 Voltmeter
3 IGBT Terminal PM3−E2
4 IGBT Terminal PM3−C1
5 Lower Capacitor Board PC3
6 IGBT Terminal PM7−C1
7 IGBT Terminal PM7−E2
6 PM7−C1 Measure the DC voltage across
screw terminals of IGBT modules
7 PM7−E2 as shown. Wait until voltage drops
to near 0 (zero) volts before pro-
ceeding.
5 NOTICE−If the capacitor voltage
does not drop to near zero after
several minutes, use a bleeder
resistor of between 25 and
500 Models 1000 Ohms, at least 5 watts,
#16 AWG 1000 volts DC insu-
2 lating rating wire to discharge
the capacitor(s).
3 PM3−E2 8 Typical Bleeder Resistor
4 PM3−C1 An example of a typical bleeder

resistor is shown on this page.
6 PM7−C1
7 PM7−E2
Typical Bleeder Resistor

25 to 1000 ohm,
5 watt resistor
#16 AWG 1000 volts DC

insulation rating, approx
3 in. (76 mm) leads
Auto−Continuum 500
Model Shown
907659TM−TP2/907640TM−TP2/907636−TP2

PRE-POWER CHECKS
10-3. Power Switch S1
! Read and follow safety informa-
tion in Section 10-1 before
proceeding.
! Wear an earth grounded wrist
Test Equipment Needed: strap when performing pre-power
W1 and power off checks. Remove
wrist strap before performing any
checks or procedures with power
applied to the machine.
! Verify that the input power cable is
isolated from primary power.
Check resistance on power switch (S1)
using ohms position on DMM Place
switch S1 to ON position. Disconnect
connector from RC1 on PC1. Disconnect
connector from RC20 on PC4.
Lead 6
1 Measure resistance from Lead 4
located on W1 contactor to Lead 14
Lead 14 Lead 16 Lead 4 located RC1−1 on PC1. Resistance
should measure below 1 ohm.
PC1
located on W1 contactor to Lead 16
located RC1−5 on PC1. Resistance
should measure below 1 ohm.
located on RC20−1 on PC4 to Lead
11 located RC20−2 on PC4. Resis-
tance should measure below 1
ohm.
4 Open switch S1. Repeat steps 1−3.
Resistance should be infinite
PC 4
PTC1
R1
RC20−1
RC20−2
Lead 11 Lead 1
RC20−3
RC20−4 PC 4
Ref. 907 640-tp1 / Ref 248916c / 265746c

PRE-POWER CHECKS
10-4. Input Contactor And Input Board PC1
! Read and follow safety informa-
tion in Section 10-1 before
proceeding.
Test Equipment Needed: strap when performing pre-power
and power off checks. Remove
wrist strap before performing any
checks or procedures with power
applied to the machine.
1 Place power switch S1 in Off
position.
2 Verify normally-open contacts of
W1 are not stuck shut by
measuring with DMM set to ohms.
3 Check resistance of W1 coil. It
should measure approximately 7
ohms.
4
Check resistance for R1 and PTC1 on
PC1 using ohms position on DMM. Verify
that the input power cable is isolated from
6
primary power. Place switch S1 in On po-
PTC1 sition.
1 Measure resistance across W1−A
located on W1 contactor to confirm
the condition of PTC1 on Input
R1
board PC1. Resistance should
measure 50 ohms at a 25C ambi-
ent. The measured value will be
higher for warmer temperatures
and lower for cooler temperatures.
2 Measure resistance across W1−C
located on W1 contactor to confirm
the condition of R1 on Input board
W1 PC1. The expected value is 40
ohms.
2 If either measured value is open,
shorted, or out of tolerance, replace
PC1.
PTC1 PC1
R1
SR1
Ref. 907 640-tp1 / Ref. 248 916C

PRE-POWER CHECKS
10-5. Input Rectifier SR1
! Read and follow safety
information in Section 10-1
before proceeding.
! Wear an earth grounded
wrist strap when performing
pre-power and power off
checks. Remove wrist strap
before performing any
checks or procedures with
power applied to the ma-
PTC1 PC1 chine.
1 Place power switch S1 in Off
position.
2 Verify condition of SR1 by
R1
using test point values and
locations listed in Section
10−6
SR1
10-6. Input Rectifier SR1 Test Point Values

1. Visually inspect components for damage. If there is visual evidence of damage such as bulging or discoloration from overheating or arcing or
if component is found to be defective using this procedure, replace PC1 and SR1.
2. Check the six input rectifier diodes within SR1 using diode position on DMM. Look for a voltage drop of 0.2 to 0 .9 VDC across the following
test points on PC1:
Positive Meter Lead Negative Meter Lead
A (AC Line 1) D (+)
B (AC Line 2) D (+)
C (AC Line 3) D (+)
F (−) A (AC Line 1)
F (−) B (AC Line 2)
F (−) C (AC Line 3)
If the input rectifier diodes are defective, check input contactor W1. See Section 10−4.

PRE-POWER CHECKS
10-7. Capacitor Boards PC2 And PC3 − 350 And 500 Models (Use With Section 10-8)
before proceeding.
Test Equipment Needed: ! Wear an earth grounded
350 Models checks. Remove wrist strap
1 power applied to the ma-
chine.
PM3−E2 1 Upper Capacitor Board PC2
PM3−C1 2 Lower Capacitor Board PC3
PM7−C1
PM7−E2
500 Models
PM3−E2
PM3−C1
PM7−C1
PM7−E2
907640TM−TP2/907636TP2
10-8. Capacitor Board PC3 − 350 And 500 Models

1. Visually inspect components for damage. If there is visual evidence of damage such as bulging or discoloration from overheating or arcing,
or if component is found to be defective using this procedure, replace as necessary.
2. Check upper and lower capacitors using diode position on DMM by connecting to following terminals. When initially connected, look for meter
value to increase, indicating a capacitor charging.
PM3−C1 PM3−E2
PM7−C1 PM7−E2

PRE-POWER CHECKS
10-9. Boost And Inverter IGBTs (Use With Sections 10-10 and 10-11)
! Read and follow safety information
in Section 10-1 before proceeding.
! Wear an earth grounded wrist strap
when performing pre-power and
Test Equipment Needed: power off checks. Remove wrist
PM2 PM3 strap before performing any checks
or procedures with power applied to
the machine.
Upper Module Pin−out

C2 E1
E2
C1
350 Models
Lower Module Pin−out

C1
E2
C2 E1
PM6 PM7
PM1 PM2 PM3 PM4
Upper Module Pin−out

C2 E1
E2
C1
500 Models
Lower Module Pin−out

C1
E2
C2 E1
PM5 PM6 PM7 PM8

PRE-POWER CHECKS
10-10. 350 Model IGBT Module Checks
1. Visually inspect IGBT modules for damage. If there is visual evidence of damage such as bulging or discoloration from overheating or arcing
or if component is found to be defective using this procedure, replace as necessary.
3. Check each module using the diode position on the DMM. Look for a voltage drop of .2 to .5 VDC. across the following terminals:
Module Positive Meter Lead Negative Meter Lead
PM2 C2 E1 C1
PM2 E2 C2 E1
PM3 C2 E1 C1
PM3 E2 C2 E1
PM6 C2 E1 C1
PM6 E2 C2 E1
PM7 C2 E1 C1
PM7 E2 C2 E1
NOTICE− Failed IGBT modules on Continuum 350 models may be replaced individually.
10-11. 500 Model IGBT Module Checks

1. Visually inspect IGBT modules for damage. If there is visual evidence of damage such as bulging or discoloration from overheating or arcing,
or if component found to be defective using this procedure, replace as necessary.
3. Check each module using the diode position on the DMM. Look for a voltage drop of .2 to .5 VDC. across the following terminals:
Module Positive Meter Lead Negative Meter Lead
PM1 C2 E1 C1
PM1 E2 C2 E1
PM2 C2 E1 C1
PM2 E2 C2 E1
PM3 C2 E1 C1
PM3 E2 C2 E1
PM4 C2 E1 C1
PM4 E2 C2 E1
PM5 C2 E1 C1
PM5 E2 C2 E1
PM6 C2 E1 C1
PM6 E2 C2 E1
PM7 C2 E1 C1
PM7 E2 C2 E1
PM8 C2 E1 C1
PM8 E2 C2 E1
NOTICE−Failed IGBT modules on Continuum 500 models must be replaced in pairs by type and location. For example, if Boost IGBT PM1
fails replace both PM1 and PM2. If Inverter IGBT PM4 fails replace both PM3 and PM4. Note that these modules are associated to Upper
Capacitor board PC2 and are isolated from IGBT modules PM5/PM6 and PM7/PM8 on Lower Capacitor board PC3. Failed IGBT modules
associated with PC3 must be replaced with a similar pairing.

PRE-POWER CHECKS
10-12. Output Diodes D1, D2, D3, D4
before proceeding.
Refer to Item 3 pre-power and power off
350 Models
below
D1 chine.
D2
Front
Rear
D1 500 Models
D2
D3
D4
Positive Weld
Output Terminal
Front
Negative Weld
Rear Output Terminal
907659TM−TP3 / 907640TM−TP3/TP4
1. Visually inspect diodes for damage. If there is visible evidence of damage such as bulging or discoloration from overheating or arcing or if
component is found to be defective using this procedure, replace the defective part.
2. First check across weld output terminals using diode position on the DMM. Look for voltage drop of 0.1 to 0 .3 VDC with leads connected as
follows. If measurement is correct proceed to next pre-power check. If measurement is incorrect perform step 3 to determine defective com-
ponent.
Negative Weld Output Terminal Positive Weld Output Terminal
3. Isolate diodes by disconnecting main transformer leads and jumper links from terminals. Check with DMM set to diode position. Look for a
voltage drop of 0.1 to 0 .5 VDC across each diode. Reconnect and torque terminals to 26 in lb/ (2.94N−m) after Pre−Power check.
350 And 500 Models
D1 Anode (Front Terminal) D1 Cathode (Base)
D1 Anode (Rear Terminal) D1 Cathode (Base)
500 Models Only

PRE-POWER CHECKS
10-13. Power Supply Board PC13 Fuse F1
Test Equipment Needed: ! Read and follow safety
before proceeding.
RC1 Fuse F1 checks or procedures with
1
chine.
1 Power Supply Board PC13
Visually inspect components for
damage. If there is visual evidence
of damage such as bulging or dis-
coloration from overheating or
arcing or if component is found to be
defective using this procedure, re-
place as necessary.
Check Fuse F1 for continuity. Re-
sistance should read less than 2
ohms. If resistance is greater that 2
ohms, replace fuse.
NOTICE−Effective with Serial No.
MG330505C, PC13 was re-
designed to use 3 amp fuses in
place of 1 amp fuses. Verify the
part number of PC13 to ensure
that the correct replacement
fuse is available and the cor-
rect circuit board is ordered (if
board replacement is neces-
sary).
RC3
RC2
907659TM−TP2 / 265 926-D

PRE-POWER CHECKS
10-14. Wire Feeder Power Board PC14 Fuse F1
Test Equipment Needed: ! Read and follow safety
before proceeding.
strap when performing
checks. Remove wrist strap be-
fore performing any checks or
procedures with power applied
to the machine.
1 Wire Feeder Power Board PC14
Visually inspect components for dam-
age. If there is visual evidence of dam-
age such as bulging or discoloration
from overheating or arcing or found to
be defective using this procedure, re-
place as necessary.
Check Fuse F1 for continuity. Resis-
tance should read less than 2 ohms.
If resistance is greater that 2 ohms,
replace fuse.
NOTICE−Effective with Serial No
MG330505C, PC14 was re-
designed to use 3 amp fuses in
place of 1 amp fuses. Verify the
part number of PC14 to ensure
that the correct replacement fuse
is available and the correct circuit
board is ordered (if board replace-
ment is necessary).
! Pre-power checks are now
complete. Remove earth
grounded wrist strap before
performing any checks or pro-
cedures with power applied to
1 the machine.
Fuse F1
RC3 RC2 RC1
907659TM−TP2 / 252 513-G

Use Sections 15 through 22 for Auto Continuum Drive Always check unit before applying power (see Section 10-1).
10-15 Troubleshooting Table
! Before connecting welding equipment to input (primary) power for servicing, be sure the input-power circuit protection is correct
for the welding equipment. Connect equipment to a dedicated circuit sized and fused for the rated output and duty cycle of the
welding equipment you are servicing. See the Electrical Service Guide section in this manual and National Electrical Code (NEC)
article 630, Electric Welders.
! Remove earth grounded wrist strap before performing any checks or procedures with power applied to the machine.
. Equipment serviced may need to meet additional requirements as specified in IEC60974-4, Arc Welding Equipment − Part 4: Periodic Inspec-
tion and Testing.
. See Section 10-18 for test points and values and Section 14 for parts location.
. Use MILLER Testing Booklet (Part No. 150853) when servicing this unit.
Trouble Remedy
Unit will not power up. Check primary panel disconnect, fuses or circuit breakers. Check input power cord and plug. Check input
power cord connections at contactor W1.
Unit powers up but does not boot Perform system reset by turning S1 to OFF position. Wait for white Power On LED to extinguish, then
properly. turn S1 to On position. If fault persists, verify Red and Green LEDs on SBC (PC19) are illuminated. Check
User Interface for error code (Section 13) Check the Boot Log for information. Check software revision
status. Perform software update.
Contactor W1 does not energize. Check W1 coil for proper connections and resistance. Check S1 contacts and connections of leads #1
and #11. Check LED indications on Arc Control board (PC4) for fault indications (see Section 10−24).
Unit powers up but has no weld output. Verify open circuit voltage at weld output terminals on power source. Check weld cable connections to
work piece and feeder. Check gun trigger contact and connections. Check User Interface for error code
(Section 13). Check LED indications on Arc Control board (PC4) for fault indications (see Section 10−24).
Weld Output is lost while welding. Check User Interface for error code (Section 13).
Wire Feeder has no power. User Inter- Check supplementary protector CB1 and reset if necessary. Verify that inverter boost circuit is active by
face does not illuminate. confirming presence of enable signal at Feeder Power Supply board (PC14) connector RC2−2.Signal
value when boost is active is 0VDC.
Wire Feeder has power but wire does Check User Interface for error code (Section 13). Check gun trigger contacts and connections. Perform
not feed. Jog test to verify motor operation.
Wire feeds erratically. Check spool hub tension and clearance.
Check drive roll pressure, wear, alignment, and cleanliness.
Check nozzle opening for weld spatter.
Check contact tip and gun cable liner.
Check gun cable for sharp tight bends or binding. Check gun for damage or overheating.
No gas flow, or continuous gas flow. Check flowmeter, hose connections, and supply pressure. Check gas valve internal hose connection, coil
resistance, and signal voltage.
Error code displayed on User Interface. Consult Error Code table for explanation and corrective action.
Auxiliary Receptacle has no power. Check supplementary protector CB 2 and reset if necessary. Check Aux. Power board (PC20) for input
bus voltage and proper connections.
Insight Core or Centerpoint data is not Check Ethernet or WiFi connections. Verify Insight mode is enabled through configuration web page. Veri-
available. fy proper configuration settings.
Software Update problems. Confirm software is properly downloaded onto USB stick. Verify User Interface can read USB stick. Verify
Ethernet communication between User Interface and Arc Control board (PC4).
Incorrect time stamps in boot log,error Update system time setting through configuration web page. Replace battery on Arc Control board (PC4).
log, or Insight data.
Poor weld result. Consult Basic Weld Troubleshooting Table.

10-16 Arc Blow

Arc blow is the deflection of the welding arc from its normal path due to magnetic forces. This condition is usually encountered in direct current welding of
magnetic materials, such as iron and nickel. Arc blow can happen in alternating current welding under certain conditions, but these cases are rare and
the intensity of the arc blow is always less severe. Direct current flowing through the electrode and base metal will set up a magnetic field around the
electrode. This magnetic field tends to deflect the arc to the side at times, but usually the arc deflects either forward or backwards along the joint.
Back blow is encountered when welding toward the work cable connection on a workpiece near the end of a joint or into a corner. Forward blow is
encountered when welding away from the work cable connection on a workpiece at the start of a joint. In general, arc blow is the result of two basic
conditions:
S The change of current flow direction as it enters the work and is conducted toward the work cable.
S The asymmetric arrangement of magnetic material around the arc, a condition that normally exists when welding is performed near the end of
ferromagnetic materials.
Although arc blow cannot always be completely eliminated, it can be controlled or reduced to an acceptable level through knowledge of the two condi-
tions listed above.
Except in cases where arc blow is unusually severe, certain steps can be taken to eliminate or reduces its severity. Some or all of the following steps
may be necessary:
S Place work cable connection as far as possible from joints to be welded.
S If back blow is the problem, place the work cable connection at the start of the joint to be welded and weld toward a heavy tack weld.
S If forward blow is the problem, place the work cable connection at the end of the joint to be welded.
S Position electrode angle so that arc force counteracts arc blow.
S Use the shortest possible arc that maintains good welding practices (this helps arc force to counteract arc blow).
S Reduce welding current if possible.
S Weld toward a heavy tack weld or runoff tab.
S Use the back step sequence of welding.
S Change to an AC welding operation which may require a change in electrode classification.
S Wrap the work cable around the workpiece in the direction that sets up a magnetic field to counteract the magnetic field causing the arc blow.
Notes

10-17 Basic Welding Troubleshooting

Listed below are some problems, causes and remedies related to welding operations; however, this list does not contain every possible condition that
could be encountered in welding.
Trouble Probable Cause Remedy

No weld output; unit completely Line disconnect switch in Off position. Place switch in On position.
inoperative.
Power source switch in Off position. Place switch in On position.
Primary power fuse blown or circuit breaker Replace fuse or reset circuit breaker and check in-
tripped. put voltage.
Weld output is present, but wire stops Wire feeder protective fuse blown or circuit breaker Replace fuse or reset circuit breaker and find over-
feeding while welding. tripped. load condition.
Wire feeder drive rolls misaligned. Align drive rolls.
Wrong size drive rolls. Replace with proper size drive rolls.
Too much or too little drive roll pressure. Adjust drive roll pressure.
Too much tension set at wire spool. Reduce wire spool tension.
Restriction in unspooler or drum adapter. Replace unspooler or repair restriction.
Feeder motor burnt out. Test motor and replace if necessary.
Gun liner dirty or restricted. Remove gun liner and clean or replace.
Wrong type or size of liner. Install proper size liner.
Broken or damaged gun or torch. Replace faulty parts.
Contact tip opening restricted. Replace contact tip.
Wrong size or type of contact tip. Replace with proper size and type contact tip.
Sharp bends or kinks in gun cable or liner. Straighten gun cable and/or replace liner.
Gun overheating. Use gun with proper amperage rating.
Wrong size wire. Match wire size to liner and contact tip.
Guides rubbing on drive rolls. Adjust or position guides properly.
Drive rolls jammed. Remove foreign object from gears.
Motor cable disconnected or damaged. Connect, repair or replace motor cable.


Porosity in weld. Dirty base metal, heavy oxides, mill scale, oil, etc. Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Regulator/flowmeter faulty. Adjust or replace regulator/flowmeter.
Gas cylinder valve closed. Open gas cylinder valve.
Gas regulator diaphragm defective. Replace regulator.
Flowmeter cracked or broken. Repair or replace flowmeter.
Gas hose disconnected or leaking. Connect or replace gas hose.
Too much or too little gas flow. Adjust for proper gas flow.
Moisture in shielding gas. Replace gas cylinder or supply.
Wrong gas for wire type or transfer mode. Use correct shielding gas.
Feeder gas solenoid faulty. Replace solenoid.
Gun or outlet cable leaking. Repair or replace faulty parts.
Wire feed speed setting too high. Reduce wire feed speed.
Contact tip extends too far out of nozzle. Adjust or replace parts (max distance should not
exceed 1/8 in (3.2 mm).
Nozzle to work distance too large. Reduce nozzle to work distance.
Incorrect gun or torch angle. Set proper gun angle (porosity or dirty welds mean
gun angle is too large).
Nozzle restriction. Clean off spatter or remove restriction.
Breeze or drafts in weld zone. Shield weld zone from drafts.
Low shielding gas cylinder pressure. Replace gas cylinder.
Gas leak at gun to feeder connection. Properly install gun or replace O-rings at gun
connector.
Excessive spatter. Voltage set too high. Reduce voltage setting (reduce trim or arc adjust
for pulse welding).
Incorrect gun or torch angle. Set proper gun angle.
Wrong electrode wire type or size. Use proper electrode wire.
Wrong inductance setting. Adjust inductance.
Electrode wire dirty or old. Replace with new electrode wire.
Oily or dirty base metal. Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Excessive wire stick-out or nozzle to work distance Adjust wire stick-out or reduce nozzle to work
too great. distance.
Wrong transfer mode. Set proper transfer mode.
Travel speed too slow. Increase travel speed so that arc is on leading edge
of weld puddle.


Wandering, hunting or erratic arc. Loose power cables or other electrical Tighten, repair or replace connections or cables,
connections. also check all rotary or brush type connections.
Incorrect gun or torch angle. Set proper gun angle.
Moisture in shielding gas. Replace gas cylinder or supply.
Wrong program selection for pulse welding. Make proper program selection.
Improper or unsteady analog command from robot Check signal from robot controller (as a trouble-
controller. shooting aid go to power source control of voltage
and wire speed).
Gun or outlet cable leaking. Repair or replace faulty parts.
Incorrect nozzle to work distance. Set proper distance [3/8 in to 5/8 in (9.5 to 15.9 mm)
for short arc, 5/8 in to 1 in (15.9 to 25.4 mm) for
pulse welding, and 3/4 in to 1-1/4 in (19.1 to 31.8
mm) for spray welding].
Voltage sensing leads open or shorted. Repair or replace voltage sense leads.
High frequency noise in the area. Be sure proper grounding methods are followed
when TIG or plasma equipment is used in the area.
Arc blow. See Section 10-16.
Drive motor tachometer or motor cable open or Check drive motor tachometer and cables, and re-
shorted. pair or replace.
Welding wire burns back to contact tip at Restriction in wire feed system. Check inlet cable, gun liner and wire guides.
the start of a weld.
Worn drive rolls. Replace drive rolls.
Improper start parameters. Adjust start parameters.
Worn contact tip. Replace contact tip.
Not enough cast in welding wire. Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip Restriction in wire feed system. Check inlet cable, gun liner and wire guides.
during welding.
Worn drive rolls. Replace drive rolls.
Worn contact tip. Replace contact tip.
Not enough cast in welding wire. Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip at Welding power source output not shutting off. Make sure all switches are in correct position,
the end of a weld. repair power source if necessary.
Burnback setting too high or too long. Adjust burnback setting or turn off completely.

10-18 Troubleshooting Circuit Diagram (Page 1 Of 2)

! Measure voltage of input capacitors according to Section
10-2, and be sure voltage is near zero before touching any
parts.
The Auto Continuum 500 model is

Test Equipment Needed: shown for troubleshooting guid-
ance. The following components are
not installed on the Continuum
350:L3, L4, PM1, PM4, PM5, PM8,
CT2, T2, D3, D4, C2/R2. The Continu-
um 350 also includes Capacitor C6 in
the primary circuit of Transformer T1.
V1
R1
R2
See Resistance
Values Table
V2 R13
V9
V1

Resistance Values
a) Tolerance − ±10% unless specified
b) Turn Off unit and disconnect input power before checking
resistance Voltage Readings
RC2−1 to RC2−5 300k ohms, disconnect plug at RC2 on PC1 a) Tolerance − ±10% unless specified
RC2−2 to RC2−5 300k ohms, disconnect plug at RC2 on PC1 b) Reference − See Below
RC2−3 to RC2−5 300k ohms, disconnect plug at RC2 on PC1 V1 325 VDC on 230 VAC input
RC2−4 to RC2−5 1k ohms, disconnect plug at RC2 on PC1 537 VDC on 380 VAC input
565 VDC on 400 VAC input
RC2−6 to RC2−5 1k ohms, disconnect plug at RC2 on PC1 650 VDC on 460 VAC input
R1−R7 Less than 1 ohm 813 VDC on 575 VAC input
R8−R10 30k ohms at 25°C (disconnect RT1, RT2, RT3) V2 1.4 VDC (Reference RC20−4)
R11−R12 3 ohms V3, V4 460 VDC (Reference E2)
R13 7 ohms V5 −15 VDC (Reference RC13−2)

V6 1 VDC per 100 A weld output (Reference RC13−2)
V7 +15 VDC (Reference RC13−2)
V8 72 VDC OCV (Reference Negative Weld Terminal)
V9 920 VDC Bus Voltage
R3 R4
V3
R5 V8
V4
R6 R7
R11 R12
V5
V6
V7
R8 R9 R10
273490-A

10-19 Troubleshooting Circuit Diagram (Page 2 Of 2)

! Measure voltage of input capacitors according to Section
10-2, and be sure voltage is near zero before touching any
parts.
Test Equipment Needed:
V1, R1
V2, R2
V6
Network
Conn.
(Rear)
Bus Positive
PC19 SBC
Bus Negative
V4
R4
V5
V5
V3, R3

Resistance Values Voltage Readings
a) Tolerance − ±10% unless specified a) Tolerance − ±10% unless specified
b) Turn Off unit and disconnect input power b) Reference − to circuit common
before checking resistance (lead 42) unless noted
R1 100 ohms V1 120 VAC RMS
R2 100 ohms V2 120 VAC RMS
R3 200 ohms V3 50 VDC (Reference RC3−7)
R4 Less than 1 ohm V4 120 VAC
V5 920 VDC Bus Voltage
V6 5 VDC
Work Sense
Robot-
Conn.
(Rear)
273490-A

10-20 Input Board PC1 Testing Information (Use With Section 10-21)
! Measure voltage of input
capacitors according to Section
10-2, and be sure voltage is near
zero before touching any parts.
1 Be sure plugs are secure before test-

ing. See Section 10-21 for values
during testing.
1 Input Board PC1
Ref. 907659TM−TP2 / Ref. 248 916C

10-21 Input Board PC1 Test Point Values

PC1 Voltage Readings b) Reference − to circuit common (lead 42)
unless noted
Receptacle Pin Type Value
RC1 1 Input Input Primary Leg L1, 230−575 volts AC with respect to RC1−5
2 −− Not Used − No Testing Required
5 Input Input Primary Leg L3, 230−575 volts AC with respect to RC1−1
RC2 1 Output L3 Inductor Current
2 Output L1 Inductor Current
3 Output L2 Inductor Current
4 Input +15 volts DC
5 Input −15 volts DC
6 Input RC4 Detect
RC3 −− −− L3 Input Inductor
RC6 −− −− Chassis Ground
RC12 1 Output Positive Rectified Primary, +280−813 volts DC with respect to RC12−5
5 Output Negative Rectified Primary, −280−813 volts DC with respect to RC12−1

10-22 Arc Control Board PC4 Testing Information (Use With Section 10-23)
! Measure voltage of input capacitors

according to Section 10-2, and be
sure voltage is near zero before
touching any parts.
Be sure plugs are secure before testing.
See Section 10-23 for values during testing.
See Section 10-24 for LED Codes.
1 Arc Control Board PC4
1 RC19 RC17 BAT 1

RC8
LED4 LED5
LED2
Green Green
Green
RC18
RC27
RC26
RC25
RC24
LED1 LED3
RC21 Amber Amber
RC20
RC10 RC9 RC23
Ref. 907659TM−TP2 / Ref. 265 746 C

10-23 Arc Control Board PC4 Test Point Values

unless noted
RC1 −− −− Not used − No Testing Required
RC2 1 −− 1 volt per 10 volts of output (sense)
2 −− 1 volt per 100 amps of output
3 −− 1 volt per 10 volts of output (stud)
4 −− 0−10 volts DC volts/trim command
5 −− 1 volt per 100 amps of output command
6 −− Common
7 −− Common
8 −− Common
RC3 1 Input +Bus, 920 volts DC with respect to RC3−5
2 −− Not used − No Testing Required
3 Input Mid Bus, 460 volts DC with respect to RC3−5
5 Input −Bus, −920 volts DC with respect to RC3−1
7 Input Negative Rectified Primary, −280−813 volts DC with respect to RC3−20
8−10 −− Not used − No Testing Required
11 −− −Bus, −920 volts DC with respect to RC3−1
13 Input Mid Bus, 460 volts DC with respect to RC3−5
15 −− −Bus, −920 volts DC with respect to RC3−1
16−19 −− Not used − No Testing Required
20 Input Positive Rectified Primary, +280−813 volts DC with respect to RC3−7
RC4 1−3 −− No Testing Required
4 −− +15 volts DC Boost with respect to RC20−1
5 −− −15 volts DC Boost with respect to RC20−1
6 −− No Testing Required
RC5 1 −− 30k ohms with respect to RC5−4, Power Off (Measure at PLG−5 with plug removed from RC−5)
2 −− 30k ohms with respect to RC5−5, Power Off (Measure at PLG−5 with plug removed from RC−5)

RC6 1−6 −− No Testing Required − Do Not Measure
RC12 1 −− Voltage Feedback, +75 volts DC with respect to RC12−5
2 −− Voltage Sense
4 −− Voltage Sense
5 −− Voltage Feedback, −75 volts DC with respect to RC12−1
RC13 1 −− No Testing Required − Do Not Measure
2 −− Circuit Common
3 −− −15 volts DC for Hall Device with respect to RC12−2
4 −− +15 volts DC for Hall Device with respect to RC12−2
5 −− No Testing Required − Do Not Measure
7 −− 0 ohms with respect to RC13−8, Power Off
8 −− 0 ohms with respect to RC13−7, Power Off
9 −− 1 volt DC per 100 amps of output with respect to RC13−2, Current Feedback
RC16 1 −− No Testing Required − Do Not Measure
RC18 Strap Chassis Ground
RC20 1 −− Boost common
2−4 −− No Testing Required − Do Not Measure

RC22 1 Input −15 volts DC Boost with respect to RC22−7
2 Output +15 volts DC with respect to RC22−7, Status
3 Input 0 volts DC with respect to RC22−7, Enable
5 Output Feedback, 1.25 volts DC with respect to RC22−7
6 Output No Testing Required − Do Not Measure, Status
7 Input GND Boost
9 Output No Testing Required − Do Not Measure, Enable
10 Output No Testing Required − Do Not Measure, Feedback
11 Input +15 volts DC Boost with respect to RC22−7
14 Input −24 volts DC Boost with respect to RC22−7
RC24 −− Comms Internal Ethernet
RC28 1−5 −− Not Used − No Testing Required
6 Input Common
7−11 −− Not Used − No Testing Required
12 Output No Testing Required − Do Not Measure, Fan AC1
13 Output No Testing Required − Do Not Measure, Fan AC2
14 Input −15 volts DC with respect to RC28−6
15 Input +15 volts DC with respect to RC28−6
17 Input −5 volts DC with respect to RC28−6
18 Output LED_Ready (Power ON LED Front Nameplate)
19 Output LED_Output (Output ON LED Front Nameplate)
20 Output LED_Overtemp (Overtemp LED Front Nameplate)

10-24 Arc Control Board PC4 LED Codes
PC4 LED Codes
. LED3 can indicate more than one fault. LED3 will blink once followed by the number of blinks for the first fault. It will blink again followed by either
the same fault code or the next fault code if there are multiple faults. LED4 and LED5 will only indicated one fault.
Indicator Number Of Meaning Corrective Action

Blinks
LED1 N/A This LED is not active
LED2 N/A This LED is not active
LED3 2 On−Board Error. SP13−Ethernet Switch Check User Interface for error code.
(Arc Control)
External N.V. Memory Cycle system power. Replace PC4
3 On−Board Error. Ethernet Switch Check User Interface for error code.
Check system power. Replace PC4.
4 Error, Feeder USART 3 Peripheral Check User Interface for error code. Cycle system power.
Check Ethernet cables and connectors from feeder to PC4
5 PC4 lost feedback messages from left feeder. Check User Interface for error code. Cycle system power.
Check Ethernet cables and connectors from feeder to PC4
6 The feeder has stopped receiving command Check User Interface for error code. Cycle system power.
Messages from PC4 Check Ethernet cables and connectors from feeder to PC4
7 On Board Error, external N.V. Flash Check User Interface for error code.
Cycle system power. Replace PC4.
8 On−Board Error, USART6−Inverter DSP Check User Interface for error code.
Cycle system power. Replace PC4
9 On−Board Error, No messages from Inverter Check User Interface for error code.
DSP Cycle system power. Replace PC4
10 PC4 lost feedback messages from right feeder Check User Interface for error code. Cycle system power.
(Dual Feeders only) Check Ethernet cables and connectors from feeder to PC4
11 Arc Voltage or Current out of limits. Check User Interface for error code. Check volt sense
Configuration and cable installation, inspect wire path.
12 System has detected a stuck wire. Check workpiece for stuck wire.
13 System has detected a missed weld. Inspect workpiece for weld quality/status.
LED4 Off Boost control missing 3.3 VDC Power Supply Check 5VDC output from Control Power Supply PC13
(Boost Control)
Check 3.3VDC signal on PC4.
On Steady On−Board Error, Boost DSP not running. Check User Interface for error code.
Cycle system power. Replace PC4.
Slow Blink Normal Operation No action required.
Slow−Fast− The self check has detected a power supply Check User Interface for error code. Check connectors on
Slow−Fast
Fault. PC4. Check voltage outputs from Con Power Supply PC13
Slow−Fast− The system has detected an input power Check User Interface for error code. Check Primary pow-
Fast−Fast er. Compare bus voltages on PC2 and PC3. Check Boost
Problem, bus voltage error, or Boost Circuit
fault. IGBTs.
Fast−Fast− On−Board error, Communication fault with Check User Interface for error code.
Fast−Fast
Inverter control or Contactor control. Cycle system power. Replace PC4

Indicator Number Of Meaning Corrective Action

Blinks
LED5 Off Inverter Control missing 3.3VDC power Check 5VDC output from Control Power Supply PC13.
(Inverter Control)
supply Check 3.3VDC signal on PC4.
On Steady On−Board error, Inverter DSP not running Check User Interface for error code.
Cycle system power. Replace PC4
Slow Blink Normal Operation No action required
Slow−Fast− The self−check circuit has detected a power Check User Interface for error code. Check connectors on
Slow−Fast
Supply fault. PC4. Check voltage outputs from Con Power Supply PC13
Slow−Fast− On−Board error, problem communicating with Check User Interface for error code.
Fast−Fast
Boost control. Cycle system power. Replace PC4
Fast−Fast− The system has detected a thermal sensor Check User Interface for error code.
Fast−Fast
Fault, overtemp condition, or loss of signal Cycle system power.
From Inverter Transformer Primary CT. Verify status and integrity or thermistors RT1, RT2, and
RT3, and/or CT1/CT2
(Continuum 350−CT1)
(Continuum 500−CT1 or CT2)
Green On Steady The Ethernet cable is connected and has Normal operation. No action required.
RJ45 LEDs
Linked the related devices.
(Each RJ45
receptacle has Ready to communicate.
an LED).
Blinking Ethernet Communication active Normal operation. No action required.
Off The Ethernet cable is not connected. Device Verify connector condition, verify positive physical connec-
tion. Test cable for continuity and isolation. Verify devices
Is not ready to communicate.
Are functioning.
Yellow On Data Speed is 100 Base−T High Speed data exchange

RJ45 LEDs
(Each RJ45
receptacle has Off Data Speed is 10 Base−T Low Speed data exchange
an LED).

10-25 Feeder Power Board PC14 Testing Information (Use With Section 10-26)
Test Equipment Needed: ! Measure voltage of input capacitors
touching any parts.
1 Control Feeder Power Board PC13
907659TM−TP2 / 252 513-G

10-26 Feeder Power Board PC14 Test Point Values

unless noted
RC1 ! High voltage present. Voltages on this receptacle can exceed 900 volts DC from chassis (GND).
NOTE: All pins on this receptacle are referenced to the primary − Bus
1 Input +Bus, 920 volts DC with respect to RC1−5

2 Input 0 volts DC with respect to RC1−5, Enable
3 Output +15 volts DC with respect to RC1−5, Status
4 Output 1.25 volts DC with respect to RC1−5, Feedback
1 Output +50 volts DC with respect to RC3−6
6 Output 50 volts common with respect to RC3−1

RC6 −− Strap Chassis Ground

10-27 Control Power Supply Board PC13 Testing Information (Use With Section 10-28)
touching any parts.
1 Power Supply Board PC14
1
907659TM−TP2 / 265 926-D

10-28 Control Power Supply Board PC13 Test Point Values

unless noted
1 Input +Bus, 920 volts DC with respect to RC1−5
2 −− Not used
3 −− Not used
4 −− Not used
6 −− Boost common
7 Output +15 volts DC boost with respect to RC1−6
11 Output −24 volts DC Boost with respect to RC1−6
14 Output −15 volts DC Boost with respect to RC1−6
RC2 1 Output −15 volts DC with respect to RC2−6
6 Output Common
9 Input Upper fan enable
10 Input Lower fan enable
16 Output Common
19 −− Chassis Ground
RC3 1 Output 120 volts AC with respect to RC3−5
2 Output 120 volts AC with respect to RC3−4
3 Output Not Used − No Testing Required
6 Output Not Used − No Testing Required
RC4 −− −− Chassis Ground

10-29 10 Pin Connector PC16 Testing Information (Use With Section 10-30 )
touching any parts.
1 10 Pin Connector PC16
2 Green and Yellow LEDs are not active
on RC1.
. RC2 is located on the underside of
1 PC16.
907659TM−TP4 / 261 839-C

10-30 10 Pin Connector PC16 Test Point Values

unless noted
RC1 −− Comms Internal Ethernet Network
RC2 A Output 50 volts common with respect to RC2 pin D or E
B Output 50 volts common with respect to RC2 pin D or E
C Input Voltage sense (positive feeder)
D Output +50 volts DC to feeder with respect to RC2 pin A or B
E Output +50 volts DC to feeder with respect to RC2 pin A or B
F Comms ENET RX−
G Comms ENET TX−
H Comms Drain
I Comms ENET TX+
J Comms ENET RX+
RC3 −− −− Chassis ground
RC4 1 Input +50 volts DC to feeder with respect to RC4−6
4 Output Voltage sense (positive feeder)
5 Input Not Used − No Testing Required
6 Input 50 volts common with respect to RC4−1

10-31 LED Board PC18 Testing Information (Use With Section 10-32)
capacitors according to Section
zero before touching any parts.
See Section 10-32 for values during
1 testing.
1 LED Board PC18
907659TM−TP5 / 256 860-D
10-32 LED Board PC18 Test Point Values

unless noted
RC1 1 Input +5 volts DC
2 Output 0.7 volts DC when machine is turned on
3 Output 0.7 volts DC when output is turned on
4 Output 0.7 volts DC when machine is in a fault condition

10-33 SBC PC19 Testing Information (Use With Section 10-34)

2 1 capacitors according to Section
RC67 zero before touching any parts.
1 2 See Section 10-34 for values during
testing.
1 SBC PC19
2 Red LED − Indicates +5VDC
supply voltage present when
illuminated.
3 Operation System Status LED−1
RC17 Green LED will blink steadily during
normal operation.
4 Operating System Status LED−2
Green LED will illuminate during
RC16 normal operation.
. The operating system is not function-
ing if either Operating System Status
LED fails to illuminate.
3 4
907659TM−TP2 / 263 175
10-34 SBC PC19 Test Point Values

unless noted
RC16 —— Comms Internal Ethernet
RC17 —— Comms External Ethernet
RC67 1 Input +5 volts DC with respect to RC67−2
2 Input Common

10-35 AIM Board PC21 Testing Information (Use With Section10−36)

See Section 10−36 for values during
testing.
1 Automation Interface Board PC34
RC25 RC28
1
RC18 RC21 J10
Front Side
RC20
RC23 RC29
RC27
RC26
Back Side
Ref. 301195-TMTP1 / Ref. 266 014-C

10-36 AIM Board PC21 Test Point Values

unless noted
RC25 1 −− +50 volts DC with respect to RC28−1
RC25 2 −− No testing required − not used
RC25 3 −− No testing required − not used
RC25 4 −− +50 volts DC with respect to RC28−1
RC26 1 Input No testing required − not used
RC26 2 Input No testing required − not used
RC27 1 Output +15 volts DC Boost with respect to (PC1) RC28−6
RC27 2 Input +15 volts DC Boost with respect to (PC1) RC28−6
RC28 1 Output 50 volts common with respect to RC28−2
RC28 2 Output +50 volts DC with respect to RC28−1
RC29 1 Input Touch Sense Voltage, +35 volts to 65 Volts DC with respect to RC29−4
RC29 2 −− Not Used
RC29 3 −− Not Used
RC29 4 Input Touch Sense Voltage Common, with respect to RC29−1
J10 1 Output +15 volts DC with respect to J10−3
J10 2 Output Do not measure − Weld output current sensor signal
J10 3 Output DC Circuit Common
J10 4 Output −15 volts DC with respect to J10−3
J10 5 Gnd Chassis Ground

10-37 User Interface Board PC34 Testing Information (Use With Section 10−38)

1 See Section 10−38 for values during
Front Side testing.
1 User Interface Board PC34
1
Back Side
Ref. 301195-TMTP1 / Ref. 266 014-C

10-38 User Interface Board PC34 Test Point Values

unless noted
RC1 1 Input +50 volts DC common
RC2 All Comms RJ45 Ethernet connection from left motor board PC31
RC3 1 −− +50 volts DC common
2 −− +50 volts DC with respect to RC3−1
RC4 All −− No testing required − not used
RC5 All −− USB connection, front side of PC34
RC6 All −− RJ45 ethernet connection
RC7 All Comms USB connection, back side of PC34
RC10 1−8 −− Switch Matrix, see Section 10-39
10 Output Program 7 LED
25 Output LED Anode
9, 11, −− No testing required − not used

14, 16,
18, 20,
22, 24,
26, 27
28 −− ESD layer
RC11 All Output LCD display connections
10-39 User Interface Board PC34 Receptacle RC10 Switch Matrix

Switch Matrix
PIN 1 2 3 4
5 Fine Adjust Program 1 Program 5 Softkey 1
6 Program 2 Program 6 Softkey 2

10-40 Checking Unit Output After Servicing

. Equipment serviced may need
to meet additional require-
ments as specified in
IEC60974-4, Arc Welding
Equipment − Part 4: Periodic
Inspection and Testing.
1 Negative Weld Output
Terminal
2 Positive Weld Output Terminal
Check open-circuit voltage be-
tween terminals according to
Section 10-18.
If correct voltage is not present,
repeat troubleshooting procedures.
Reinstall cover and side panels if
removed.
Negative
Positive
2 1
907659TM−TP6
Notes

10-41 Load Bank Mode

The Continuum Power Source must be set to Load Bank Mode prior to testing on a load bank. One of the weld programs must be temporarily reconfig-
ured for load bank operation. The program can be configured for a CC or CV output.
The electrode and work lead cables are disconnected from the weld terminals for the load bank test. Test cables or adapters may be needed for con-
necting the power source to the load bank. The wire feeder interface cable remains connected as the User Interface must be powered up for the test.
Refer to the Operator’s Manual or the data card on the Continuum power source for rated output values. The maximum rated load test is performed in
the CC mode. Follow the instructions for the load bank in use to ensure safe operation and meaningful test results.
Load Bank mode is enabled through the Status menu on the User Interface. Rotate the Scroll knob until the Load Bank Mode menu item is selected.
Note that the status is indicated as Off. Press the Scroll button to enter the selection. A progress bar will display the transition into load bank mode. The
status indicator will now be On.
The next step is to create a load bank program, as follows:

S Press any of the eight weld program buttons.
S Press the Setup button and select Load New Process. Press the Scroll button to enter the selection.
S Rotate the Scroll knob to select Load Bank CC or Load Bank CV. Press the Scroll button to enter the selection.
S Select the Volt Sensing Mode. Stud is most common. If Sense is selected the Voltage Sensing lead must be connected to the negative weld
cable connection at the load bank. Press the Scroll button to enter the selection.
S The default wire type is No Wire. Press the Scroll button to enter the selection.
S Select Load Bank Motor On or Off as desired. Most tests will be performed with the motor off. If the motor is selected On, wire will be fed at the
programmed rate if threaded through the drive rolls. Press the Scroll button to enter the selection.
S Complete the load bank program configuration by pressing the Scroll button again.
A progress bar indicates that the program is loading. When loading is complete the selected program is ready for use with the load bank test. Enter the
desired test parameters through the controls on the User Interface. Turn the weld output on and off by pressing the Scroll button, by pulling/releasing the
gun trigger, or by using a remote switch connected to the trigger receptacle on the wire feeder.
The Continuum unit will automatically exit Load Bank mode when the power is cycled OFF. Load Bank mode can be manually selected Off through the
Status menu.
Notes

SECTION 11 − MAINTENANCE
11-1. Routine Maintenance
! Disconnect power . Maintain more often

before maintaining. during severe conditions.
n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent
Every l Unreadable Labels ~ Weld Terminals nl Weld Cables nl Gun Cables

3
Months
nl Cords nl Cracked Parts ~ Weld Connections n Tighten Weld Cable

Connections
Every
6 OR
Months
~ Inside Unit
11-2. Blowing Out Inside Of Unit
! Do not remove case when

blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers.
907659TM−TP1
TM-257 798 Page 82 Auto−Continuum 350 and 500

SECTION 12 − ERROR CODE TROUBLESHOOTING

DESCRIPTION AND TABLES
ERR BTN STUK
2 ERROR
3
4
Button on UI stuck
Make sure all buttons are clear
If error persists, please contact support.

Logs
5
Ref. 266 061-B
1 LED Display Message ERROR- The system has experienced a 3 LCD Display Message
fault that must be addressed before contin- Provides more information about the mes-
Displays a short message describing the uing use. sage being displayed.
error or where the error is occurring. Some MESSAGE- No fault has occurred, but 4 LCD Solution Message
messages may represent multiple different some action must be taken before resum- Describes the action needed to clear the
errors. For more specific error information ing use of the welding system. For message or fault being experienced.
see the LCD Display Message. instance, input power may need to be
5 Logs Soft Key
cycled after loading new software.
Pressing the Logs soft key will take the us-
2 Message Type
WARNING- There is something that er to the Logs Menu. From the Logs Menu
should be addressed before continuing. it is possible to access the Error Log. The
There are three types of messages that will For instance, the volt sense lead connec- LCD Error Log Messages are stored in the
be displayed. tion has been lost. Error Log.

LED Display Message LCD Solution LCD Error Log

LCD Display Message
Message Type Message Message
Unit was not ready for a weld se-
WELD WAIT ERROR Press button to clear error Weld Wait Error
quence
Allow unit too cool then cycle
ERR OVERTEMP ERROR Welding power source has overheated Overtemp Error
power
Reset the emergency stop
E STOP ERROR Emergency stop activated E Stop
button
OVER CURRENT Welding power source primary draw Check input primary then cy-
ERROR Primary Overcurrent
too high cle power
Cycle power on the power
CYCLE POWER MESSAGE The unit requires a power cycle Cycle Power Error
source
OVER POWER ERROR
SLF TST ERR ERROR Welder failed self test Self Test Error
source
Ensure your primary voltage is
ERR INPT PWR ERROR Input Power Problem Input Power Problem
correct
ERR FDR ERROR Feeder Power Problem Feeder Power Problem
source
ERR AUX PWR ERROR AUX Power Problem AUX Power Problem
source
ERR THERM ERROR Thermal System Problem Thermal System Problem
source
ERR PWR SRC ERROR Welder Power Source Problem Power Source Problem
source
ERR WFS ERROR Actual WFS does not match command Press button to clear error Wire Speed Error
ERR STRT ERROR Trigger held too long without arc Press button to clear error Arc Start Error
Potential obstruction in wire feed sys- Check wire feed and wire
ERR STOP ERROR Arc Stop Error
tem drive systems
ERR GAS FLW ERROR No gas flow to the gun Check gas connections Gas Flow Error
ERR COOL FLW ERROR No coolant flow in water system Check water cooling system Coolant Flow Error
Check and repair feeder weld
ERR GND CRNT ERROR Weld current detected in earth ground Earth Ground Current Error
connections
Wire stick to workpiece at the end of Break/Cut wire away from
ERR WIR STUK ERROR Wire Stuck Error
the weld workpiece
Check wire feeder and power
ERR ARC ERROR Arc Outage occurred Arc Outage Error
source
Release trigger and cycle
ERR TRG STUK ERROR Trigger held during power up Trigger Stuck Error
power
ERR SOFTWARE Incompatible software detected in the
ERROR Update software Incompatible Software Error
system
ERR FEEDER ERROR Feeder peripheral malfunction Feeder EEPROM Error
source
ERR FEEDER ERROR Feeder peripheral malfunction Feeder USART1 Error
source
ERR COMM FDR ERROR Feeder Lost Comms to Arc Controller Check the control cable Feeder lost comms to AC
ERR FDR PWR ERROR Feeder power fault Feeder bus overcurrent error
source
ERR FDR PWR ERROR Feeder power fault Feeder bus current fault
source
ERR FDR RLY ERROR Feeder power relay stuck open Feeder relay stuck open
source
ERR FDR ETH ERROR Feeder Ethernet switch malfunction Feeder Ethernet switch error
source
source
source
ERR FEEDER ERROR Feeder peripheral malfunction Feeder SPI2 Error
source


LCD Display Message
Feeder has lost tachometer wire
ERR FDR TACH ERROR Feeder lost tach signal error
speed feedback
Make sure all buttons are
ERR BTN STUK ERROR Button on UI stuck UI Button Stuck
clear
ERR COMM UI ERROR UI Lost Comms to the Sequencer Check the control cable UI lost comms to Seq
FACTORY RST ERROR Factory Reset Complete Factory Reset
source
UNUSED 218 ERROR Unused Error #218 Unused Error #218
source
ERR INPT PWR ERROR Must use three phase primary power Check primary connections Single Phase Error
ERR INPT PWR ERROR Primary input voltage too high Check primary connections High Input Voltage Error
ERR INPT PWR ERROR Primary input voltage too low Check primary connections Low Input Voltage Error
source
ERR FEEDER ERROR Feeder input voltage too high Feeder Voltage High Error
source
ERR FEEDER ERROR Feeder input voltage too low Feeder Voltage Low Error
source
source
Too much current draw from AUX Cycle power on the power
ERR AUX PWR ERROR AUX Power Overcurrent Error
power port source
ERR AUX PWR ERROR AUX power module overheated AUX Power Overtemp Error
source
ERR AUX PWR ERROR AUX power voltage too high AUX Voltage High Error
source
ERR AUX PWR ERROR AUX power voltage too low AUX Voltage Low Error
source
source
Allow welder to cool then cy-
ERR THERM 1 ERROR Thermistor 1 overtemp THERM1 Overtemp Error
cle power
cle power
cle power
ERR THERM 1 ERROR Thermistor 1 shorted THERM1 Shorted Error
source
source
source
ERR THERM 1 ERROR Thermistor 1 open THERM1 Open Error
source
source
source
source
ERR PWR SRC ERROR Invalid device configuration Invalid Power Source Config
source
ERR PWR SRC ERROR Output current sensor malfunction Output Current Sensor Error
source
Inverter −15V power supply out of reg- Cycle power on the power
ERR PWR SRC ERROR Inverter −15V Power Error
ulation source
Inverter +15V power supply out of reg- Cycle power on the power
ERR PWR SRC ERROR Inverter +15V Power Error
ulation source
ERR PWR SRC ERROR Invalid inverter device configuration Invalid Inverter Config
source
ERR PWR SRC ERROR Inverter primary CT error Inverter Primary CT Error
source
ERR PWR SRC ERROR Boost fault Boost Fault Error
source

LCD Display Message
ERR PWR SRC ERROR Boost contactor error Boost Contactor Error
source
ERR PWR SRC ERROR Boost CS1 current error Boost CS1 Error
source
source
source
source
ERR PWR SRC ERROR Boost current balance error Boost Current Balance Error
source
ERR PWR SRC ERROR Boost overcurrent error Boost Overcurrent Error
source
ERR PWR SRC ERROR Boost precharge error Boost Precharge Error
source
ERR PWR SRC ERROR Boost bus balance error Boost Bus Balance Error
source
ERR PWR SRC ERROR Boost bottom bus cap voltage high Boost Bottom Bus Cap V High
source
ERR PWR SRC ERROR Boost top bus cap voltage high Boost Top Bus Cap V High
source
ERR PWR SRC ERROR Invalid boost device configuration Invalid Boost Config
source
Boost −15V power supply out of regu- Cycle power on the power
ERR PWR SRC ERROR Boost −15V Power Error
lation source
Boost −24V power supply out of regu- Cycle power on the power
ERR PWR SRC ERROR Boost −24V Power Error
lation source
Boost +15V power supply out of regu- Cycle power on the power
ERR PWR SRC ERROR Boost +15V Power Error
lation source
Inspect volt sense lead for
WRN VSNS LOS WARNING Lost volt sense lead feedback Vsense Fallback Warning
break
ERR UNKNOWN
ERROR An unknown error has occurred Update software Unknown Error

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

SECTION 13 − ELECTRICAL DIAGRAMS

. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram Wiring Diagram
Auto−Continuum 350 Welding MG140540C thru MG480508C 273 905-A ♦♦

Power Source
Auto−Continuum 350 Welding MG480509C and following 273 905−B Table 13−1
Power Source
Circuit Board PC1 MG140540C and following 248 917-C ♦♦ ♦♦

(Input Board)
Continuum 350 MG140540C and following 265 949-A ♦♦ ♦♦

Circuit Board PC3
(350A Capacitor Board)
Circuit Board PC4, Insight MG140540C and following 265 747-D ♦♦ ♦♦

(Arc Control Board)
Circuit Board PC13 MG140540C thru MG330504C 252 514-G ♦♦ ♦♦

(Control Feeder Power Board)
Circuit Board PC13 MG330505C and following 275 215-A ♦♦ ♦♦

(Control Power Supply Board)
Circuit Board PC14 MG140540C thru MG330504C 265 927-D ♦♦ ♦♦

(Power Supply Board)

(Feeder Power Board)

(10-Pin Connector)

(LED Board)
Circuit Board PC19 MG140540C and following ♦♦ ♦♦

(Wega SBC Board)

(User Interface Board)
♦♦ Not included in this manual

Auto−Continuum 500 Welding MG140540C thru MG480508C 273 490−A ♦♦

Power Source
Auto−Continuum 500 Welding MG480509C and following 273 490-B Table 13−2
Power Source

(Input Board)
Continuum 500 MG140540C and following 248 922-D ♦♦ ♦♦

Circuit Boards PC2 and PC3
(500A Capacitor Board)
Circuit Board PC4, Insight MG140540C and following 265 747-D ♦♦ ♦♦

(Arc Control Board)
Circuit Board PC13 MG140540C thru MG330504C 265 927-G ♦♦ ♦♦


Circuit Board PC14 MG140540C thru MG330504C 252 514-D ♦♦ ♦♦



(10-Pin Connector)

(LED Board)
Circuit Board PC19 MG140540C and following ♦♦ ♦♦

(Wega SBC Board)

(User Interface Board)
The above is a list of all diagrams for models covered by this manual.

Figure 13-1. Circuit Diagram For Auto−Continuum 350 Models Eff w/Ser No MG140540C Thru MG480508C
(Page 1 of 2)
273 905-A

(Page 2 of 2)
273 905-A

Figure 13-3. Circuit Diagram For Auto-Continuum 350 Models Eff w/Ser No MG480509C And Following
(Page 1 of 2)

273 905-B

Figure 13-4. Circuit Diagram For Auto-Continuum 350 Models Eff w/Ser. No. MG480509C And Following (Page 2 of 2)
273 905-B

(Page 1 of 2)

273 490-A

(Page 2 of 2)
273 490-A

Figure 13-7. Circuit Diagram For Auto-Continuum 500 Models Eff w/Ser No MG480509C And Following
(Page 1 of 2)

273 490-B

Figure 13-8. Circuit Diagram for Auto-Continuum 500 Models Eff w/Ser No MG480509C And Following (Page 2 of 2)
273 490-B

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Table 13-1. Lead List Summary For Auto−Continuum 350 Models Eff w/MG480509C
. Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of conductive electric compound (Part No. 603978) to terminals where factory-applied compound had been
present.
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146557) to connectors where factory-applied
grease had been present.
Lead Connections Lead Connections

0001A S1 (L1) TO PLG20 (1) 0037C CP1 (OUT) TO PLG36 (1)
0004B W1 (L3) TO S1 (L2) 0037D CP1 (OUT) TO PLG36 (4)
0006B W1 (L1) TO S1 (L3) 0037E CP1 (OUT) TO PLG3 (1)
0007A W1 (T1) TO SR1 (A) 0037F PLG47 (1) TO RC36 (1)
0008A W1 (T2) TO SR1 (B) 0037G RC65 (1) TO RC1
0009A W1 (T3) TO SR1 (C) 0037H RC36 (4) TO PLG65 (1)
0011A S1 (T1) TO PLG20 (2) 0038A PM1 (E2) TO PLG3 (3)
0012A W1 (COIL) TO PLG20 (4) 0039A PLG3 (20) TO PLG42 (1)
0014B S1 (T2) TO PLG1 (1) 0041A PC2 (RC1) TO PM8 (C1)
0016B S1 (T3) TO PLG1 (5) 0042A CHASSIS GND TO PLG32 (19)

0042C GND REAR BASE TO RC15 (GND)
0021A PLG12 (1) TO (+) OUTPUT STUD
0042D GND REAR BASE TO RC15 (NEUTRAL)
0021B PLG79 (1) TO (+) OUTPUT STUD
0043A PLG2 (1) TO PLG4 (1)
0022A NEGATIVE OUTPUT STUD TO L5
0044A PLG2 (2) TO PLG4 (2)
0022B PLG12 (5) TO (−) OUTPUT STUD
0045A PLG2 (3) TO PLG4 (3)
0022C PLG79 (4) TO (−) OUTPUT STUD
0046A PLG2 (4) TO PLG4 (4)
0024A PLG33 (1) TO RC40 (1)
0047A PLG2 (5) TO PLG4 (5)
0025A PLG33 (2) TO RC41 (1)
0048A PLG2 (6) TO PLG4 (6)
0026A PLG33 (5) TO RC40 (2)
0049A PLG31 (11) TO PLG22 (14)
0027A PLG33 (4) TO RC41 (2)
0052B PLG31 (7) TO PLG22 (13)
0028A RC34 (1) TO PLG5 (1)
0053B PLG31 (6) TO PLG22 (7)
0029A RC34 (2) TO PLG5 (4)
0054B PLG31 (14) TO PLG22 (1)
0030A PLG35 (1) TO PLG5 (2)
0055A PLG28 (15) TO PLG77 (2)
0031A PLG35 (2) TO PLG5 (5)
0056A PLG28 (6) TO PLG32 (6)
0032A RC38 (1) TO PLG5 (3)
0057A PLG28 (14) TO PLG32 (1)
0033A RC38 (2) TO PLG5 (6)
0058A PLG28 (16) TO PLG32 (5)
0034A PLG13 (7) TO PLG13 (8)
0059A PLG28 (12) TO PLG32 (9)
0035A CP2 (IN) TO PC3 (RC1) 0060A PLG28 (13) TO PLG32 (10)
0035B CP2 (IN) TO PLG31 (5) 0061A PC2 (RC3) TO PC2 (RC5)
0035C CP2 (IN) TO PLG36 (3) 0061A PLG32 (16) TO PLG82 (2)
0035D CP2 (IN) TO PLG36 (6) 0062A PC3 (RC3) TO PC3 (RC4)
0035E CP2 (IN) TO PLG3 (5) 0062A PLG32 (15) TO PLG82 (1)
0035F PLG47 (5) TO RC36 (3) 0073B PC1 (RC6) TO UPPER WT (GND)
0035G RC65 (3) TO RC2 0073B PC13 (RC4) TO LOWER WT (GND)
0035H RC36 (6) TO PLG65 (3) 0081A PLG22 (12) TO PLG37 (1)
0036A PM5 (C1) TO PLG3 (13) 0081B RC80 (1) TO RC7
0037A CP1 (OUT) TO PM1 (C1) 0081C PLG80 (1) TO RC37 (1)
0037B CP1 (OUT) TO PLG31 (1) 0082A PLG22 (9) TO PLG37 (2)
0082B RC80 (2) TO RC9 0117A PLG81 (4) TO PLG74 (1)
0082C PLG80 (2) TO RC37 (2) 0117B PLG12 (2) TO RC74 (1)
0083A PLG22 (6) TO PLG37 (3) 0118A PLG81 (6) TO PLG49 (6)
0083B RC80 (3) TO RC8 0119A PLG49 (1) TO PLG75 (1)
0083C PLG80 (3) TO RC37 (3) 0119B PLG75 (4) TO CB1
0084A PLG22 (10) TO PLG37 (4) 0120A L6 TO LEAD 120B
0084B RC80 (4) TO RC10 0120B LEAD 120A TO RC3
0084C PLG80 (4) TO RC37 (4) 0121A L6 TO LEAD 121B
0085A PLG22 (11) TO PLG37 (5) 0121B LEAD 121A TO RC4
0085B PLG48 (1) TO RC37 (5) 0122A RC15 (NEUTRAL) TO 122B
0087A PLG22 (3) TO PLG37 (7) 0122B LEAD 122A TO RC5
0087B PLG48 (2) TO RC37 (7) 0123B CB2 TO RC6
0088A PLG22 (5) TO PLG37 (8) 0124A RC15 (HOT) TO CB2
0088B PLG48 (4) TO RC37 (8) 0127A RC3 (B) TO PLG12 (4)
0089A PLG22 (2) TO PLG37 (9) 0128A R3 TO PLG49 (7)
0089B PLG48 (3) TO RC37 (9) 0129A R3 TO PLG49 (2)
0109A CB1 TO PLG81 (1) 0139A PLG83 (2) TO PLG49 (3)
0111A PLG55 (1) TO PLG56 (1) 0141B PLG46 (1) TO RC59 (3)
0111B PLG28 (17) TO RC56 (1) 0142B PLG46 (2) TO RC59 (6)
0114B PLG28 (19) TO RC56 (4) 0149A PLG78 (2) TO RC49 (4)

Table 13-2. Lead List Summary For Auto−Continuum 500 Models Eff w/MG480509C
. Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of conductive electric compound (Part No. 603978) to terminals where factory-applied compound had been
present.
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146557) to connectors where factory-applied
grease had been present.

0001A S1 (L1) TO PLG20 (1) 0037H RC36 (4) TO PLG65 (1)
0004B W1 (L3) TO S1 (L2) 0038A PM1 (E2) TO PLG3 (3)
0006B W1 (L1) TO S1 (L3) 0039A PLG3 (20) TO PLG42 (1)
0007A W1 (T1) TO SR1 (A) 0040A PLG3 (7) TO PLG42 (5)
0008A W1 (T2) TO SR1 (B) 0041A PC2 (RC1) TO PM8 (C1)
0009A W1 (T3) TO SR1 (C) 0042A CHASSIS GND TO PLG32 (19)
0011A S1 (T1) TO PLG20 (2) 0042C GND REAR BASE TO RC15 (GND)
0012A W1 (COIL) TO PLG20 (4) 0042D GND REAR BASE TO RC15 (NEUTRAL)
0014B S1 (T2) TO PLG1 (1) 0044A PLG2 (2) TO PLG4 (2)
0016B S1 (T3) TO PLG1 (5) 0045A PLG2 (3) TO PLG4 (3)
0021A PLG12 (1) TO (+) OUTPUT STUD 0046A PLG2 (4) TO PLG4 (4)
0021B PLG79 (1) TO (+) OUTPUT STUD 0047A PLG2 (5) TO PLG4 (5)
0022A NEGATIVE OUTPUT STUD TO L5 0048A PLG2 (6) TO PLG4 (6)
0022B PLG12 (5) TO (−) OUTPUT STUD 0049A PLG31 (11) TO PLG22 (14)
0022C PLG79 (4) TO (−) OUTPUT STUD 0052B PLG31 (7) TO PLG22 (13)
0024A PLG33 (1) TO RC40 (1) 0053B PLG31 (6) TO PLG22 (7)
0025A PLG33 (2) TO RC41 (1) 0054B PLG31 (14) TO PLG22 (1)
0026A PLG33 (5) TO RC40 (2) 0055A PLG28 (15) TO PLG77 (2)
0027A PLG33 (4) TO RC41 (2) 0056A PLG28 (6) TO PLG32 (6)
0028A RC34 (1) TO PLG5 (1) 0057A PLG28 (14) TO PLG32 (1)
0034A PLG13 (7) TO PLG13 (8) 0073B PC1 (RC6) TO UPPER WT (GND)
0035A CP2 (IN) TO PC3 (RC1) 0073B PC13 (RC4) TO LOWER WT (GND)
0035B CP2 (IN) TO PLG31 (5) 0081A PLG22 (12) TO PLG37 (1)
0035C CP2 (IN) TO PLG36 (3) 0081B RC80 (1) TO RC7
0035D CP2 (IN) TO PLG36 (6) 0081C PLG80 (1) TO RC37 (1)
0035E CP2 (IN) TO PLG3 (5) 0082A PLG22 (9) TO PLG37 (2)
0035F PLG47 (5) TO RC36 (3) 0082B RC80 (2) TO RC9
0035G RC65 (3) TO RC2 0082C PLG80 (2) TO RC37 (2)
0035H RC36 (6) TO PLG65 (3) 0083A PLG22 (6) TO PLG37 (3)
0036A PM5 (C1) TO PLG3 (13) 0083B RC80 (3) TO RC8
0037A CP1 (OUT) TO PM1 (C1) 0083C PLG80 (3) TO RC37 (3)
0037B CP1 (OUT) TO PLG31 (1) 0084A PLG22 (10) TO PLG37 (4)
0037C CP1 (OUT) TO PLG36 (1) 0084B RC80 (4) TO RC10
0037D CP1 (OUT) TO PLG36 (4) 0084C PLG80 (4) TO RC37(4)
0037E CP1 (OUT) TO PLG3 (1) 0085A PLG22 (11) TO PLG37 (5)
0037F PLG47 (1) TO RC36 (1) 0085B PLG48 (1) TO RC37 (5)
0037G RC65 (1) TO RC1 0087A PLG22 (3) TO PLG37 (7)
0087B PLG48 (2) TO RC37 (7) 0120B LEAD 120A TO RC3
0088A PLG22 (5) TO PLG37 (8) 0121A L6 TO LEAD 121B

0089A PLG22 (2) TO PLG37 (9) 0122A RC15 (NEUTRAL) TO 122B
0098A PLG32 (2) TO PLG77 (1) 0123B CB2 TO RC6
0109A CB1 TO PLG81 (1) 0124A RC15 (HOT) TO CB2
0111A PLG55 (1) TO PLG56 (1) 0127A RC3 (B) TO PLG12 (4)
0111B PLG28 (17) TO RC56 (1)
0128A R3 TO PLG49 (7)
0112A PLG55 (2) TO PLG56 (2)
0129A R3 TO PLG49 (2)
0112B PLG28 (18) TO RC56 (2)
0138A PLG83 (1) TO PLG49 (8)
0113A PLG55 (3) TO PLG56 (3)
0139A PLG83 (2) TO PLG49 (3)
0113B PLG28 (20) TO RC56 (3)
0141B PLG46 (1) TO RC59 (3)
0114A PLG55 (4) TO PLG56 (4)
0142B PLG46 (2) TO RC59 (6)
0114B PLG28 (19) TO RC56 (4)
0143B PLG28 (7) TO RC59 (1)
0117A PLG81 (4) TO PLG74 (1)
0119B PLG75 (4) TO CB1 0148A PLG78 (1) TO PLG49 (9)

0120A L6 TO LEAD 120B 0149A PLG78 (2) TO PLG49 (4)

TM-273473A 2017−08
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Arc Welding Power Source
Auto−Continuum
®
350 And 500

w/ Insight Coret
Eff w/ Serial No. MG140540C

And Following

and more, visit
www.MillerWelds.com
SECTION 14 − PARTS LIST FOR 350 AND 500 MODELS
5 Figure 14-7
6
2
12 Figure 14-6
20
19
21
13
14 Figure 14-2
23
15 Figure 14-3
24
16 21
10
18 8 Figure 14-4
3
11
1 17
22
7
9
Figure 14-5
274585-B
Figure 14-1. Main Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity
350 500
Model Model
. . 1 . . . . . . . . . . . . . +265236 . . Base ,Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 269888 . . . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . 1 . . . . . 1
. . 2 . . . . . . . . . . . . . +265245 . . Panel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258431 . . . . Label, Warning General Precautionary (CE/Domestic) . . . . . . 1 . . . . . 1
. . 3 . . . . . . . . . . . . . +265246 . . Panel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258431 . . . . Label, Warning General Precautionary (CE/Domestic) . . . . . . 1 . . . . . 1
. . 4 . . . . . . . . . . . . . +265240 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258427 . . . . Label, Warning Falling Equipment . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 5 . . . . . . . . . . Figure 14-7 . . Rear Panel Assy, Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 274551 . . Bracket, Guard Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 7 . . . . . . . . . . . . . . 273400 . . Output Terminal Assy, (See Figure 14-5) . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 8 . . . . . . . . . . Figure 14-4 . . Fan Panel Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 9 . . . . . . . . . . Figure 14-5 . . Front Panel Assy, Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 10 . . . . . . . . . . . . . . 269472 . . Gasket, Sealing 17.000L x .250w x .063t . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . . . . . 273390 . . Assy, UI Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 12 . . . . . . . . . . Figure 14-6 . . Penthouse Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 13 . . . . . . . . . . . . . . 270511 . . Insulator,.010 Thick X 4.500 X 8.000 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 14 . . . . . . . . . . Figure 14-2 . . Windtunnel, Rh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 15 . . . . . . . . . . Figure 14-3 . . Windtunnel, Lh W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 16 . . . . PC1 . . . . 248915 . . Circuit Card Assy, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 17 . . . . PC4 . . . . 273420 . . Circuit Card Assy, Inverter - Arc Control Auto W/Prog . . . . . . . . 1 . . . . . 1
. . 18 . . . . PC13 . . . . 265925 . . Circuit Card Assy, Power Supply (Prior to MG330505C) . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 258016 . . . . Fuse, Mintr Cer 1 Amp 1000V AC/DC . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 18 . . . . PC13 . . . . 275213 . . Circuit Card Assy, Power Supply (Eff w/MG330505C) . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 275235 . . . . Fuse, Mintr Cer 3 Amp 1000V AC/DC . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 19 . . . . . . . . . . . . . . 271671 . . Circuit Card Assy, AIM Continuum w/Prog . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 20 . . . . HD2 . . . . 182918 . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . 1 . . . . . 1
. . 21 . . . . . . . . . . . . . . 266420 . . Plate, Lift Eye Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 22 . . . . . . . . . . . . . . 267407 . . Plate, Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 23 . . . . . . . . . . . . . . 273487 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 24 . . . . . . . . . . . . . . 269271 . . Insulator, Windtunnel/Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 262913 . . Kit, Strain Relief 1.250 (Including) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 255675 . . . . Bushing, Strain Relief .865/1.26 Id x 1.250 Mtg Hole . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 263092 . . . . Nut, Conduit 1.250 Npsm Knurled . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 602177 . . . . Screw, Set 250−20 x .25 Knrlpt Sch stl Pln . . . . . . . . . . . . . . . . 1 . . . . . 1 . .
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

. Hardware is common and
not available unless listed.
20
21
6
4 7
22
14
19 17 3
1
13
16
15
18
5 9 12
2 10
8 11 Ref. 269 780-C
Figure 14-2. Right-Hand Windtunnel w/Components
Item Dia. Part

Figure 14-2. Right-Hand Windtunnel 350 500
w/Components (Figure 14-1, Item 14) Model Model
. . 1 . . . . . . . . . . . . . . 265243 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 2 . . . . T1-T2 . . . 252442 . . Xfmr, Hf Litz (500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 2
. . 2 . . . . . T1 . . . . . 267776 . . Xfmr, Hf Litz (350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . . . . . . . . . . . . . . . . . . 263299 . . Heat Sink Assy, Output Diode (500)(Includes Items 3-7) . . . . . . 0 . . . . . 1
. . . . . . . . . . . . . . . . . . . 267924 . . Heat Sink Assy, Output Diode (350)(Includes Items 3-7) . . . . . . 1 . . . . . 0
. . 3 . . . . . . . . . . . . . . 213029 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 26.00in Lead . . . . . 1 . . . . . 1
. . 4 . . . . . . . . . . . . . . 199840 . . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 5 . . . . . . . . . . . . . . 272416 . . . . Heat Sink, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 233052 . . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 2
. . 7 . . . D1−D4 . . . 201531 . . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 8 . . . . . . . . . . . . . . 196355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4
. . 9 . . . . . . . . . . . . . . 025248 . . Stand-off, Insul .250-20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . 2 . . . . . 2
. . 10 . . . . . . . . . . . . . . 236727 . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . . . . . 179276 . . Bushing, Snap-in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . 2 . . . . . 2
. . 12 . . . . . . . . . . . . . . 253547 . . Bus Bar, Xfmr Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 13 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . 1 . . . . . 1
. . 14 . . . . . L5 . . . . . 273683 . . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 15 . . . . . . . . . . . . . . 223343 . . Clip, Wire Stdf .40-.50 Bndl .156hole .031-.078thk . . . . . . . . . . . 2 . . . . . 2
. . 16 . . . . . . . . . . . . . . 267438 . . Plate, Blank Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 17 . . . . . C5 . . . . . 265285 . . Capacitor,Polyp Met Film 30. Uf 550 Vdc . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . 18 . . . . . . . . . . . . . . 057360 . . Blank, Snap-In Nyl 1.375 Mtg Hole Black . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . 19 . . . . . . . . . . . . . . 267870 . . Plate, Mtg Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . 20 . . . . PC20 . . ♦271474 . . Circuit Card Assy, 115v Aux Power w/Prog & Potted . . . . . . . . . 1 . . . . . 1
. . 21 . . . . . . . . . . . . ♦271483 . . Bracket, Mtg Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 22 . . . . . . . . . . . . ♦271775 . . Inductor, Output Continuum Aux Module . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
♦OPTIONAL
not available unless listed. 7
10
1
2
12
11
5
4
269 781-A
Figure 14-3. Left-Hand Windtunnel w/Components
Item Dia. Part

Figure 14-3. Left-Hand Windtunnel 350 500
w/Components (Figure 14-1, Item 15) Model Model
. . 1 . . . . L1-L4 . . . . 252375 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 2 . . . . . . . . . . . . . . 265242 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 3 . . PC2-PC3 . . 248920 . . Circuit Card Assy, Capacitor (500) . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 2
. . 3 . . PC2-PC3 . . 265947 . . Circuit Card Assy, Capacitor (350) . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 0
. . 4 . . . . . . . . . . . . . . 259517 . . Kit, Transistor IGBT Module (Inverter) . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 5 . . . . . . . . . . . . . . 259515 . . Kit, Transistor IGBT Module (Boost) . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 4
. . 6 . . . . . . . . . . . . . . 252449 . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.00in Lead . . . . . . . 1 . . . . . 1
. . 7 . . . . . . . . . . . . . . 173632 . . Thermistor, Ntc 30k Ohm @ 25 Deg C 12.00in Lead . . . . . . . 1 . . . . . 1
. . 8 . . . . . . . . . . . . . . 262497 . . Stand-off Support, PC Card .156 Dia W/P&L 1.125 . . . . . . . . . . 1 . . . . . 1
. . 9 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . 4 . . . . . 6
. . 10 . . . . . . . . . . . . . . 266939 . . Heat Sink, Igbt Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . . . . . 266940 . . Heat Sink, Igbt Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 12 . . . . . . . . . . . . . . 184260 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . . . . . . 047838 . . Blank, Snap-In Nyl 1.000 Mtg Hole Black . . . . . . . . . . . . . . . . . . . 2 . . . . . 0
. . . . . . . . . . . . . . . . . . . 267386 . . Plate, Input Inductor Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 0

4 5
1 3
269 782-B
Figure 14-4. Fan Panel Assembly
Item Dia. Part

Figure 14-4. Fan Panel Assembly (Figure 14-1, Item 8)
. . 1 . . . . . . . . . . . . . . 265241 . . Panel, Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . FM1-FM2 . . 213072 . . Fan, Muffin 115v 60hz 3400 Rpm 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 2
. . 3 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 3
. . 5 . . . . . . . . . . . . . . 153403 . . Bushing, Snap-in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . . 2

Notes

5
4
3
2
24
19
7
9 17
15
14 20
16
23 22
8 21
13
10 12
11
18
274588A
Figure 14-5. Front Panel Assembly

Item Dia. Part
Figure 14-5. Front Panel Assembly (Figure 14-1, Items 7, 9)
. . 1 . . . . . . . . . . . . . . 252825 . . Bezel, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 253548 . . Panel, Top Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 256859 . . Circuit Card Assy, Led . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 261870 . . Cover, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 252445 . . Switch, Rotary On/Off 3PH 20Amp 600V 2 Layer . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 265467 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 7 . . . . . . . . . . . . . . 252821 . . Enclosure, Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 8 . . . . . . . . . . . . . . 262325 . . Panel, Front Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 265239 . . Panel, Output Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 269799 . . . Terminal Pwr Assy, Output Tabbed (Includes) . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 260223 . . . . Terminal, Pwr Output Tabbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 186228 . . . . O-ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 250037 . . . . Insulator, Bulkhead Front .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 185718 . . . . O-ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 250039 . . . . Insulator, Bulkhead Rear .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 185714 . . . . Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 185717 . . . . Nut, M20-1.5 1.00hex .19h Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 269800 . . . Terminal Pwr Assy, Output Front Bolted Rear (Includes) . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . . . 252830 . . . . Terminal, Pwr Output Front Bolted Rear Int Thread . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 186228 . . . . O-ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 250037 . . . . Insulator, Bulkhead Front .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 185718 . . . . O-ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 250039 . . . . Insulator, Bulkhead Rear .890 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 185714 . . . . Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 185717 . . . . Nut, M20-1.5 1.00hex .19h Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . . . 229333 . . Screw, M10-1.5x 20 Hex Hd-pln 8.8 Pld Sems . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 256961 . . Lead List, Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . C4 . . . . . 138695 . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . VR2 . . . . 269178 . . . Varistor, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 23 . . . . . . . . . . . . . . 057359 . . Blank, Snap-in Nyl .375 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . 273488 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 605603 . . . Tubing, Gl Acryl 1.000−1.036 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate Continuum (Order By Model & Serial No.) . . . . . . . . . . 1

10 2
11 8
3
6
4 7
1
5
269784-C
Figure 14-6. Penthouse Assembly
Item Dia. Part

Figure 14-6. Penthouse Assembly (Figure 14-1, Item 12)
. . 1 . . . . . . . . . . . . . . 245520 . . Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent . . . . . . . . . . . . . . . . 7

. . 2 . . . . . W1 . . . . . 180270 . . Contactor, Def Prp 40a 3p 24vac Coil W/Boxlug . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 275142 . . Bracket, Mtg Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 145743 . . Lug, Univ W/Scr 600V 2-14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . +265238 . . Panel, Upper Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 155436 . . . . Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 136076 . . Resistor, Ww Fxd 30 W 200 Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . +265261 . . Lift Eye, Formed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 266393 . . . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 266232 . . Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 256975 . . Seal, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . PC19 . . . . 273411 . . Assy, Communication Package Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 262090 . . Feeder Power Board Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PC14 . . . . 252512 . . . . Circuit Card Assy, Control Feeder Pwr (Prior to MG330505C) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 258016 . . . . . . Fuse, Mintr Cer 1 Amp 1000V AC/DC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PC14 . . . . 275221 . . . . Circuit Card Assy, Control Feeder Pwr (Eff. W/MG330505C) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 275235 . . . . . . Fuse, Mintr Cer 3 Amp 1000V AC/DC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 262089 . . . . Bracket, Feeder Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 8
14 . Hardware is common and
6
1 5
10 4
7 11
12
2
13
3
Ref. 274590B
Figure 14-7. Rear Panel Assembly

Item Dia. Part
Figure 14-7. Rear Panel Assembly (Figure 14-1, Item 5)
. . 1 . . . . . . . . . . . . . +273395 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 258429 . . . . Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 274436 . . . . Label, E−Stop−Peripherals Auto−Continuum . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate Rear (Order By Model And Serial Number) . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 257290 . . Panel, Rear Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 263536 . . Rail, Din 35mm X 7.5mm X 1.969in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . PC16 . . . . 261838 . . Circuit Card Assy, Power Source 10 Pin Filter . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . CB1 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 269208 . . Plugs, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 260822 . . Antenna,Rf Monopole 2.4ghz Screw Mount . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 275563 . . Cable Assy, Rj45 Male/M12 Female .4m Lg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 275313 . . Panel, Rear Enet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 269416 . . . . Label,Ethernet/Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 271543 . . Cable Assy,Rf Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . RC15 . . ♦214918 . . Rcpt, Str Dx Grd 2p3w 20a 125v 5−20r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . ♦257289 . . Panel, Rear Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . ♦252139 . . Cover, Receptacle Duplex GFCI Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . CB2 . . ♦093995 . . Supplementary Pro, Man Reset 1p 15a 250Vac . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL

Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2017 Miller Electric Mfg. Co. 2017−01
TM-273476A 2017−08
Eff. w/Serial No. MG050520C
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Description
Wire Feeder
Auto−Continuum Drive
R
CE

and more, visit
www.MillerWelds.com
INFORMATION ON OLDER UNITS
. This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com
. This manual provides service and repair information for the Auto−Continuum 350 and 500 and Auto−Continuum Drive assembly. The Auto−Con-
tinuum 350 and 500 information is located in TM273473.
TABLE OF CONTENTS
SECTION 15 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

15-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
15-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
15-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
15-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SECTION 16 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
16-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
16-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
16-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
16-4. Wire Type, Size, And Wire Feed Speed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
16-5. Overall Dimensions And Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
SECTION 17 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17-1. Typical Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17-2. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17-3. Remote 10 Wire Feeder Control Receptacle RC2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
17-4. Connecting Weld Output Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
17-5. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
17-6. Installing Wire Guides And Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
17-7. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
SECTION 18 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
18-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
SECTION 19 − AUTO CONTINUUM DRIVE THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
SECTION 20 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
20-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
20-2. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
20-3. Boom/Dual Motor Board PC36 Testing Information (Use With Section 20−4) . . . . . . . . . . . . . . . . . . . . 138
20-4. Motor Control Board PC36 Test Point Values (Use With Section 20−3) . . . . . . . . . . . . . . . . . . . . . . . . 139
20-5. 10 Pin Connector PC35 Testing Information (Use With Section 20−6 ) . . . . . . . . . . . . . . . . . . . . . . . . . 140
20-6. 10 Pin Connector PC35 Test Point Values (Use with Section 20−5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
20-7. Measuring Wire Feed Speed (WFS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
SECTION 21 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
SECTION 22 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
SECTION 15 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
15-1. Symbol Usage

OM-266408F 2016−04, safety_stm 2015-09
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.
15-2. Servicing Hazards
The symbols shown below are used throughout this manual STATIC (ESD) can damage PC boards.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Put on grounded wrist strap BEFORE handling
to avoid the hazard. boards or parts.
Only qualified persons should test, maintain, and repair this D Use proper static-proof bags and boxes to
unit. store, move, or ship PC boards.
During servicing, keep everybody, especially children, away.

FIRE OR EXPLOSION hazard.
ELECTRIC SHOCK can kill. D Do not place unit on, over, or near combustible
surfaces.
D Do not touch live electrical parts. D Do not service unit near flammables.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re-
ceptacle, or stop engine before servicing unless the procedure spe- FLYING METAL or DIRT can injure eyes.
cifically requires an energized unit.
D Wear safety glasses with side shields or face
D Insulate yourself from ground by standing or working on dry insulat-
shield during servicing.
ing mats big enough to prevent contact with the ground.
D Be careful not to short metal tools, parts, or
D Do not leave live unit unattended.
wires together during testing and servicing.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free. HOT PARTS can burn.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source. D Do not touch hot parts bare handed.
D Allow cooling period before working on
SIGNIFICANT DC VOLTAGE exists in inverter weld- equipment.
ing power sources AFTER removal of input power. D To handle hot parts, use proper tools and/or wear heavy, insu-
D Turn Off inverter, disconnect input power, and discharge input lated welding gloves and clothing to prevent burns.
capacitors according to instructions in Troubleshooting Section be-
fore touching any parts.
EXPLODING PARTS can injure.
ARC FLASH can kill.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
Arc flash is the rapid and violent release of energy that
occurs when electric current leaves its intended path D Always wear a face shield and long sleeves
and arcs to other conductors or to ground. Arc flash when servicing inverters.
can be caused by equipment failure (faulty insulation,
corrosion, dust) improper installation, human error (improper tool
placement), and other factors. Conductive vapors can sustain the
arc until over-current devices open the circuit. Individuals within
the arc flash boundary are at risk.
SHOCK HAZARD from testing.
D Do not work on energized equipment unless an assessment of D Turn Off welding power source and wire feeder
arc flash risk from the electrical supply circuit has been conducted or stop engine before making or changing me-
by a qualified person and you have been trained in safe work prac- ter lead connections.
tices by your employer. D Use at least one meter lead that has a self-
D Follow requirements in NFPA 70E for safe work practices and retaining spring clip such as an alligator clip.
Personal Protective Equipment (PPE). D Read instructions for test equipment.
TM-273476 Page 122 Auto−Continuum Drive

FALLING EQUIPMENT can injure. OVERUSE can cause OVERHEATING.
D Use lifting eye to lift unit only, NOT running D Allow cooling period; follow rated duty cycle.
gear, gas cylinders, or any other accessories. D Reduce current or reduce duty cycle before
D Use equipment of adequate capacity to lift and starting to weld again.
support unit. D Do not block or filter airflow to unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit. H.F. RADIATION can cause interference.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu- D High-frequency (H.F.) can interfere with radio
ally lifting heavy parts or equipment. navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician prompt-
MOVING PARTS can injure. ly correct any interference problem resulting from the installa-
tion.
D Keep away from moving parts such as fans.
D If notified by the FCC about interference, stop using the
D Keep away from pinch points such as drive equipment at once.
rolls.
D Have the installation regularly checked and maintained.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance and D Keep high-frequency source doors and panels tightly shut, keep
troubleshooting as necessary. spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D Keep hands, hair, loose clothing, and tools
away from moving parts.
D Reinstall doors, panels, covers, or guards READ INSTRUCTIONS.
when maintenance is finished and before re-
connecting input power. D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
ELECTRIC AND MAGNETIC FIELDS (EMF) D Use only genuine replacement parts from the manufacturer.
can affect Implanted Medical Devices. D Read and follow all labels and the Technical Manual carefully be-
fore installing, operating, or servicing unit. Read the safety in-
D Wearers of Pacemakers and other Implanted
formation at the beginning of the manual and in each section.
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the D Perform installation, maintenance, and service according to the
device manufacturer. Technical Manual, industry standards, and national, state, and
local codes.
15-3. 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. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
15-4. EMF Information

Electric current flowing through any conductor causes localized electric 17. Do not coil or drape cables around your body.
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and 18. Keep head and trunk as far away from the equipment in the
induction heating operations) creates an EMF field around the welding welding circuit as possible.
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants 19. Connect work clamp to workpiece as close to the weld as
have to be taken. For example, restrict access for passers−by or con- possible.
duct individual risk assessment for welders. All welders should use the
20. Do not work next to, sit or lean on the welding power source.
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 21. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
15. Keep cables close together by twisting or taping them, or using a
cable cover. Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
16. Do not place your body between welding cables. Arrange cables If cleared by your doctor, then following the above procedures is recom-
to one side and away from the operator. mended.
Auto−Continuum Drive TM-273476 Page 123

SECTION 16 − SPECIFICATIONS
16-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
16-2. Specifications
Input Power Welding Power Wire Feed Speed Range* Wire Diameter Range Welding Overall Weight
Source Type Circuit Rating Dimensions
50 VDC Continuum Standard: .035 To .5/64 in. NON CE Height:

Series 50−1000 ipm (0.9 To 2 mm) 75 Volts 9 1/4 in.
(1.27−25.4mpm) 500 Amperes, (235 mm)
100% Duty Width:
Cycle 9 15/32 in.
(241 mm) 16.5 lb
Length: (7.5 kg)
CE
13 in.
75 Volts (330 mm)
400 Amperes
100% Duty
Cycle
*See Section 16-4 for detailed information on wire type, wire size, and wire feed speed.
16-3. Environmental Specifications

A. IP Rating
IP Rating
IP21S
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21S 2014−06
B. Information On Electromagnetic Compatibility (EMC)
! This Class A equipment is not intended for use in residential locations 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 well as radiated disturbances.
ce-emc 3 2014-07
C. Temperature Specifications
Operating Temperature Range Storage/Transportation Temperature Range
14 to 104°F (−10 to 40°C) −4 to 131°F (−20 to 55°C)

Temp1_016- 08
TM−273476 Page 124 Auto−Continuum Drive

D. China EEP Hazardous Substance Information

质量
China EEP Hazardous Substance Information
部

质
Component Name Hazardous Substance
(适) 铅镉铬醚
(if applicable) Pb Hg Cd Cr6 PBB PBDE
黄铜铜部
X O O O O O
Brass and Copper Parts
装
X O O O O O
Coupling Devices
!"装
O O X O O O
Switching Devices
#$#$配
Cable and Cable X O O O O O
Accessories
%
X O O O O O
Batteries
&表'*+SJ/T 11364规-.0.
This table is prepared in accordance with China SJ/T 11364.
O:
表5该
质7该部8 9质:;量97GB/T26572规-限量要?@A.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表5该
质CD7该部EF9质:;量超HGB/T26572规-限量要?.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
IKLM限*+SJ/Z11388规-O-.

The EFUP value of this EEP is defined in accordance with China SJ/Z 11388. EEP_2016−06
16-4. Wire Type, Size, And Wire Feed Speed Table
Wire Size .035 .045 .052 .062 5/64
MIG: MIG: MIG: MIG:

50 To 1000 ipm 50 To 1000 ipm 50 To 800 ipm 50 To 600 ipm
(1.27 to 25.40 mpm) (1.27 to 25.40 mpm) (1.27 to 20.22 mpm) (1.27 to 15.24 mpm)
Solid Steel N/A
Accupulse: Accupulse: Accupulse: Accupulse:
75 To 1000 ipm 50 To 1000 ipm 50 To 800 ipm 50 To 600 ip
MIG: MIG: MIG:

50 To 1000 ipm 50 To 900 ipm 50 To 700 ipm
(1.27 to 25.40 mpm) (1.27 to 22.86 mpm) (1.27 to17.78 mpm)
Metalcore Steel N/A N/A
Accupulse: Accupulse: Accupulse:
50 To 800 ipm 50 To 700 ipm 50 To 600 ipm
(1.27 to 20.32 mpm) (127 to 17.78 mpm) (1.27 to 15.24 mpm)
MIG: MIG: MIG: MIG:

Flux cored Steel N/A 200 To 900 ipm 200 To 900 ipm 150 To 800 ipm 100 To 400 ipm
Auto−Continuum Drive TM−273476 Page 125

16-5. Overall Dimensions And Mounting Hole Layout
Wire Drive Assembly Inches Millimeters
A 10 254
B *10 *254
C 8 3/4 222
A
*B
*Length includes gas filter
Mounting Holes
Inches Millimeters
A B
A 7.250 184
B 0.626 16
C 7.666 195
D 3.500 89
E 4.351 111
C
F 3.696 95
G 3.569 101
H 3.250 83
D E G H
301207−013

SECTION 17 − INSTALLATION
17-1. Typical Equipment Location
5
4
6
3
2
1 Welding Power Source 4 Weld Control 6 Wire Drive Assembly

2 Gas Cylinder 5 Spool Support 7 Automatic Welding Gun
3 Side Beam
ST-131 138-A
17-2. Connections
1 Jog/Retract Switch
2 10-Socket Control Receptacle RC3
3 Gas Purge Switch
Connect control cable from rear of welding
power source to wire drive assembly.
To make connections, align keyway, insert
plug, and tighten threaded collar.
4 Shielding Gas Valve Fitting
1
Requires hose fitting with 5/8-18
right-hand threads.
For guns requiring external gas connec-
tions, remove hose from barbed fitting near
gun/feeder opening and connect to gun.
2
301207−013

17-3. Remote 10 Wire Feeder Control Receptacle RC2 Information
A +50 Volts DC Common
B +50 Volts DC Common
C Voltage Sense
D +50 Volts DC Power
E +50 Volts DC Power
A H
I
F ENET Rx −
B G
J F
C
D E
G ENET Tx −
H Drain
I ENET Tx +
J ENET Rx +
301207-010
Notes

17-4. Connecting Weld Output Cable
! Turn off power before connecting to
Tools Needed: weld output tabs or receptacles.
9/16 in. (14 mm)
! Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
9/16 in. (14 mm) Ensure all connections are tight.
Tab Connection
. Do not place anything between weld

cable terminal and output tab. Make
sure that the surfaces of the weld cable
terminal and output tab are clean.
Single Feeder
2/0 And Larger Double Cables
4 Incorrect Weld Cable Connection
5 Weld Output Terminal Bolt
6 Nut
8 Output Terminal
Remove supplied nut and bolt from weld
output terminal. Insert bolt through hole in
weld cable terminal and hole in weld output
terminal. Screw nut onto bolt until weld cable
terminal is tight against output terminal.
Rear View
1
2 4
5 6
8 7
7
5 8 7 6
2/0 and larger double cables
301207−010 / Ref. 259 120-B

17-5. Installing Welding Gun
1 Power Clamp Knob
2 Gun Locking Tab
3 Gun Locking Tab Rotated 180
Degrees
4 Power Pin Groove
5 Gun Connection End
Installing gun with Accu-Mate
connection
Loosen power clamp knob to allow
power pin of gun to clear the gun
locking tab.
Push power pin into power clamp
as far as possible to align the
groove in the power pin of the gun
with the gun locking tab.
Secure gun by tightening power
clamp knob.
Installing gun without Accu-
Mate connection
When using a gun without the
groove in the power pin, loosen
5 power clamp knob and rotate gun
locking tab 180 degrees. This pre-
vents the locking tab from extend-
ing into the power pin gun connec-
tion.
Push power pin into power clamp
as far as possible.
Secure gun by tightening power
4 clamp knob.
Installing gun with Installing gun without

Accu-Mate connection Accu-Mate connection
1 2 1 3
276492-B / ref. 270 026-A / Ref. 260233-B

17-6. Installing Wire Guides And Drive Rolls
1
7 8
9
10
11
301207-13 / Ref. 274356-B
Installing Wire Guide And Drive Rolls 9 Thumb Screw Pull drive roll shaft and remove drive roll
1 Drive Roll Tension Assembly Install inlet wire guide into anti-wear guide, carrier. Install drive roll, rotate securing ring
and secure with setscrew. until it stops at a detent position, place carri-
Open tension assembly. er back into tension assembly bracket, and
2 Drive Roll Bracket Screw Loosen thumb screw.
secure carrier with drive roll shaft. Do the
3 Drive Roll Bracket Push inlet guide into opening until groove same for the remaining tension
aligns with thumb screw. Tighten thumb assembly.
4 Drive Roll Carrier And Securing Ring screw to secure inlet guide.
Remove bracket screw. 10 Intermediate Wire Guide . Never close Tension Assembly if Drive
Remove drive roll bracket. Roll Bracket (3) is removed.
. Shoulder on intermediate wire guide Aligning Wire Guide And Drive Rolls
5 Drive Roll faces to rear of drive housing.
Rotate securing rings until tabs line up with Push in intermediate guide locking button Self-aligning drive rolls do not require any
grooves in drive rolls. Remove drive rolls manual adjustment.
and push intermediate guide into opening
from carriers. until groove is secured by locking button. Cleaning Drive Rolls
6 Intermediate Guide Locking Button Install drive rolls and drive roll bracket. Remove drive rolls, and clean grooves
7 Anti-Wear Guide Secure bracket with screw. using a wire brush.
8 Inlet Wire Guide 11 Upper Drive Roll Shaft Close drive assembly cover.

17-7. Installing And Threading Welding Wire
Tools Needed:
. Hold wire tightly to keep it from unraveling.
6 in.
(150 mm)
Turn on power at welding power source. Pull and hold wire; cut off end.
Drive Back Of Gun

Rolls
Pressure
Indicator
Scale
Pressure
Adjust
End Of Liner
WOOD
. For best wire feeding performance, be . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
sure that the outlet cable has the proper steel wire, reduce drive roll pressure on about 2 in. (51 mm) from nonconductive
size liner for the welding wire size being the rear roll to half that of the front rolls. surface and press jog button to feed wire
used. Also, when the gun is installed, the against surface. Tighten knob so wire
liner extending from the back of the gun does not slip. Do not overtighten. If
should be as close to the drive rolls as contact tip is completely blocked, wire
possible, without touching. should slip at the feeder (see pressure
adjustment above).Cut wire off. Close
Install gun. Lay gun cable out straight. Cut off
cover.
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
242 517-A / Ref. 156 798-A / Ref. 269 820-A

SECTION 18 − MAINTENANCE
18-1. Routine Maintenance
! Disconnect power . Maintain more often

before maintaining. during severe conditions.
n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent
l Unreadable Labels ~ Weld Terminals nl Weld Cables nl Gun Cables
Every
3
Months
nl Cords nl Cracked Parts ~ Weld Connections n Tighten Weld Cable
Connections
l Damaged Gas Hose

Every
6 OR
Months
~ Drive Rolls ~ Inside Unit
Notes

Notes

SECTION 19 − AUTO CONTINUUM DRIVE THEORY OF
OPERATION
1 10-Pin Receptacle RC2
Provides 50 volts DC input power, voltage sense
feedback, and ethernet communications from weld- 2
ing power source.
2 Motor Board PC36 1
50 volts DC
10-Pin
• Controls wire speed by changing the pulse Voltage Sense
Receptacle
width modulation signal (wider or narrower
pulses meaning more or less voltage to motor) RC2 Ethernet Comm.
after comparing motor speed feedback signals
to wire speed command.
• Motor speed is regulated using the motor en-
coder feedback signal. 3
• Energizes gas valve. Purge
3 Purge Switch S2 Switch
S2
S1 is a single throw switch. When switch is pressed
down, gas valve will operate, providing shielding gas
to flow.
4 Jog/Retract Switch S1
S1 is a dual throw switch. When switch is pressed
up, wire is jogged without engaging weld output or
gas valve. When switch is pressed down, wire is re- 4
tracted without engaging weld output or gas valve. Motor
These functions are mainly used during wire spool Jog/Retract Board
changes. Switch PC36
5 Wire Drive Motor M1 S1
Feeds wire at a speed set by Arc Controller Board in
welding power source. Motor speed is regulated by 5
motor board PC36.
Drive Motor
6 Motor Encoder M1
Converts motor RPM to a pulsed feedback signal
used by motor board PC36 to regulate speed of wire
drive motor M1. 512 pulses are generated for every 6
revolution of drive motor armature.
Motor
7 Gas Valve GS1 Encoder
35 volt DC valve provides shielding gas during the
weld cycle.
7
Gas Valve
GS1
AC, DC, or Ethernet Control Circuits

SECTION 20 − TROUBLESHOOTING
20-1. Troubleshooting Table
! Before connecting welding equipment to input (primary) power for servicing, be sure the input-power circuit protection is correct
for the welding equipment. Connect equipment to a dedicated circuit sized and fused for the rated output and duty cycle of the
welding equipment you are servicing. See the Electrical Service Guide section in this manual and National Electrical Code (NEC)
article 630, Electric Welders.
! Remove earth grounded wrist strap before performing any checks or procedures with power applied to the machine.
. Equipment serviced may need to meet additional requirements as specified in IEC60974-4, Arc Welding Equipment − Part 4: Periodic Inspec-
tion and Testing.
. See Section 20−2 for test points and values and Section 22 for parts location.
. Use MILLER Testing Booklet (Part No. 150853) when servicing this unit.
Trouble Remedy
Wire feeds, shielding gas flows, but Check and secure weld cable connections (see Section 17−4).
electrode wire is not energized.
Electrode wire feeding stops or feeds Check gun trigger connection. See gun Owner’s Manual.
erratically during welding.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure (see Section 17−7).
Change to correct size drive roll (see Section 16−4).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Check drive motor or motor control board PC1.
Wire feeder power is on, displays light Check welding gun trigger leads for continuity, and repair leads or replace gun.
up, but unit is inoperative.
Notes

20-2. Troubleshooting Circuit Diagram
V1
V1
V2
V3
Tach A
Tach B
V4
V4
Voltage Readings
a) Tolerance − ±10% unless
specified
b) Reference − to circuit common
(lead 42) unless noted
V1 +50 volts DC
V2 +30 volts DC
V3 +5 volts DC
V4 0 to 48 volts DC
Tach Readings
A, B 0.128 or 4.50 volts DC when
off, 2.4 volts DC running,
1.5kHz to 18kHz
274640-B

20-3. Boom/Dual Motor Board PC36 Testing Information (Use With Section 20−4)
Be sure plugs are secure before test-
ing. See Section 20−4 for values
during testing.
1 Boom/Dual Motor Interface
Board PC36
RC20
274707−E / Ref. 266460-E

20-4. Motor Control Board PC36 Test Point Values (Use With Section 20−3)

unless noted
RC1 All −− No testing required
RC3 A Input +50 volts DC common
RC5 1 −− No testing required
2 −− No testing required
3 Input +Positive voltage feedback
2 Input 0.128 or 4.59 volts DC at rest, 2.4 volt DC when running. 1.5kHz to 19kHz min to max when running.
3 Output Tach common
4 Input 0.128 or 4.59 volts DC at rest, 2.4 volt DC when running. 1.5kHz to 19kHz min to max when running.
RC7 1 Output 0 to +48 volts DC when motor is running with respect to RC7−3
2 −− No testing required − not used
3 Output 0 to +48 volts DC when motor is running with respect to RC7−1
RC8 1 Output Digital ground, DGND
2 Output +50 volts DC common
RC10 1, 2 −− No testing required
RC11 1 Output Output to left gas valve. Will spike to +50 volts DC and hold at 30 volts DC with respect to RC11−2.
2 Output Left gas solenoid common
RC12, RC13, All −− No testing required

RC15, RC18,
RC20
2 Output +50 volts DC common

20-5. 10 Pin Connector PC35 Testing Information (Use With Section 20−6 )
See Section 20−6 for values during testing.
1 10 Pin Connector PC36
2 Green and Yellow LEDs are not active
on RC1.
. RC3 is located on the underside of
PC35.
274707−E / 261 839-C

20-6. 10 Pin Connector PC35 Test Point Values (Use with Section 20−5)

unless noted
RC1 −− Comms Internal Ethernet Network
RC2 −− −− Chassis ground
RC3 A Output 50 volts common with respect to RC2 pin D or E
B Output 50 volts common with respect to RC2 pin D or E
C Input Voltage sense (positive feeder)
D Output +50 volts DC to feeder with respect to RC2 pin A or B
E Output +50 volts DC to feeder with respect to RC2 pin A or B
F Comms ENET RX−
G Comms ENET TX−
H Comms Drain
I Comms ENET TX+
J Comms ENET RX+
RC4 1 Output +50 volts DC to motor board with respect to RC4−2
4 Output Voltage sense (positive feeder)
5 Output +50 volts DC to motor board with respect to RC4−5

20-7. Measuring Wire Feed Speed (WFS)
1 Thumbscrew
2 Shaft Assembly Support Cover
3 Gear Idler Pin (2)
Remove the thumbscrew, shaft assembly
RPM
support cover, and gear idler pins.

4 Pinion Drive Gear
Press tachometer against pinion drive gear
to determine revolutions per minute (RPM).
Multiply RPM by 3.9548 to calculate wire
feed speed (WFS).
RPM x 3.9548 = WFS
Ref. 301195-TMTP3

SECTION 21 − ELECTRICAL DIAGRAM
Auto−Continuum Drive MG500502C and following 274640-B ♦♦
Motor Control Board PC36 MG050520C and following 266461-E♦♦
10 Pin Filter Board PC35 MG050520C and following 262440-E♦♦

274640-B
Figure 21-1. Circuit Diagram for Auto Drive Feeders Eff w/Ser No MG500502C And Following

TM-273476A 2017−08
Eff. w/Serial No. MG050520C
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Description
Wire Feeder
Auto−Continuum R
Drive
Eff w/Serial No.

MG050520C And Following

and more, visit
www.MillerWelds.com
SECTION 22 − PARTS LIST
5
13
12
7
11
16
17
15
6
14
8
4 3 19
2
10
18
9
20 − Figure 22-3
3
Ref. 274772-E
Figure 22-1. Main Assembly (Left)

Item Dia. Part
. . 1 . . . . . . . . . . . . . . 276333 .. Bracket, Mtg Auto−Continuum Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 275200 .. Base, Auto−Continuum Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 265352 .. Tubing, Polyurethane Blk .197 Id X .315 OD X 18.000 . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . . 228035 .. Valve, 34vdc 1way .750−14 Thd 2mm Orf 100psi . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . +276419 .. Wrapper, Auto−Continuum Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . +276352 .. Label, Nameplate Auto−Continuum Drive Front . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 276354 .. Label, Nameplate Auto−Continuum Drive Rear . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 276424 .. Insulator, Base Auto−Continuum Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 276423 .. Plate, Adapter Mtg Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 276524 .. Insulator, Mylar .014 X 6.500 X 6.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 270484 .. Switch,W/Leads (Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 268554 .. Plug, W/Leads (Dual Gas Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 275318 .. Label, Warning General Precautionary (En/Fr/SP−Sym) . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 275806 .. Label, Warning Hot Surfaces And Moving Parts . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . PC36 . . . . 273421 .. Circuit Card Assy, Motor/Feeder Comm Boom/Dual/Auto . . . . . . . . . . . . . 1
. . 16 . . . . PC35 . . . . 262437 .. Circuit Card Assy, Feeder 10 Pin Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 211989 .. Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . . . 279847 .. Ftg, Gas Push To Conn Straight 5/16 In Od Tubing . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . . . 267552 .. Insulator, Mylar .014 X 2.000 X 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . Figure 22-3 .. Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 271079 .. Cable, Ethernet Cat6 Ftp Rj45 12.000 In Lg (Right . . . . . . . . . . . . . . . . . . 1

13
5
16
14
15
8
7
3
12
2 19
11
4
17
10
18 9
20 − Figure 22-4 3
Ref. 278487-B
Figure 22-2. Main Assembly (Right)

Item Dia. Part
. . 1 . . . . . . . . . . . . . . 276333 .. Bracket, Mtg Auto−Continuum Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 275200 .. Base, Auto−Continuum Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 265352 .. Tubing, Polyurethane Blk .197 Id X .315 OD X 18.000 . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . . 228035 .. Valve, 34vdc 1way .750−14 Thd 2mm Orf 100psi . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . +276419 .. Wrapper, Auto−Continuum Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . +275584 .. Label, Nameplate Auto−Continuum Drive Front (Right) . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 275580 .. Label, Nameplate Auto−Continuum Drive Rear (Right) . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 276424 .. Insulator, Base Auto−Continuum Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . . 276423 .. Plate, Adapter Mtg Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 276524 .. Insulator, Mylar .014 X 6.500 X 6.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 270484 .. Switch,W/Leads (Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 268554 .. Plug, W/Leads (Dual Gas Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 275318 .. Label, Warning General Precautionary (En/Fr/SP−Sym) . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 275806 .. Label, Warning Hot Surfaces And Moving Parts . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . PC36 . . . . 273421 .. Circuit Card Assy, Motor/Feeder Comm Boom/Dual/Auto . . . . . . . . . . . . . 1
. . 16 . . . . PC35 . . . . 262437 .. Circuit Card Assy, Feeder 10 Pin Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 211989 .. Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . . . 279847 .. Ftg, Gas Push To Conn Straight 5/16 In Od Tubing . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . . . 267552 .. Insulator, Mylar .014 X 2.000 X 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . Figure 22-4 .. Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 263237 .. Cable, Ethernet Cat6 Ftp Rj45 14.000 In Lg . . . . . . . . . . . . . . . . . . . . . . . . 1

14
13
11
12
10
2 1
8
4
15
3
9
7
6
5
Ref. 274772-E
Figure 22-3. Drive Assembly (Left)

Item Dia. Part
Figure 22-3. Drive Assembly (Figure 22-1, Item 20)
. . 1 . . . . . . . . . . . . . . 275201 . . Block, Inlet Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 276525 . . Screw, Thumb Stl ..250−20 x .375 Pld Nylon Head . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 275202 . . Assy, Power Pin Block Lh (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 275203 . . . . Block, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 073432 . . . . Ftg, Hose Brs Barbed M 3/16 Tbg X 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 277263 . . . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 262703 . . . . Lock, Power Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 262691 . . . . Clamp, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 010836 . . . . Pin, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 251557 . . . . Spring, Cprsn .210 Od X .026 Wire X 1.000 Pld . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 253589 . . Hub, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 276332 . . Insulator, Motor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 275492 . . Bus Bar,Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 257630 . . Motor, Gear 1/11hp 40vdc R Angle Lh Boom . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 279953 . . Encoder, Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 261787 . . Plug, W/Cable (Encoder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . Figure 22-5 . . Wire Drive Assembly, No Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14
13
11
3 4
12
9 10
8
6
5
15
2 1
Ref. 278487-B
Figure 22-4. Drive Assembly (Right)

Item Dia. Part
Figure 22-4. Drive Assembly (Figure 22-1, Item 20)
. . 1 . . . . . . . . . . . . . . 275201 . . Block, Inlet Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 276525 . . Screw, Thumb Stl ..250−20 x .375 Pld Nylon Head . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 275202 . . Assy, Power Pin Block Lh (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 275203 . . . . Block, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 073432 . . . . Ftg, Hose Brs Barbed M 3/16 Tbg X 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 277263 . . . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 262703 . . . . Lock, Power Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 262691 . . . . Clamp, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 010836 . . . . Pin, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 251557 . . . . Spring, Cprsn .210 Od X .026 Wire X 1.000 Pld . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 253589 . . Hub, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 276332 . . Insulator, Motor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 278305 . . Bus Bar,Power Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 257629 . . Motor, Gear 1/11hp 40vdc R Angle Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 279953 . . Encoder, Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 261787 . . Plug, W/Cable (Encoder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . Figure 22-5 . . Wire Drive Assembly, No Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 3
13
10
11
4
7
12 9
276492-B
Figure 22-5. Wire Drive Assembly, No Motor
Item Dia. Part

Figure 22-5. Wire Drive Assembly, No Motor (Figure 22-3, Item 15)
.. 1 .............. 260262 .. Assy, Pressure Arm Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 2 .............. 260263 .. Assy, Pressure Arm Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 3 .............. 259150 .. Spring, Double Torsion .408 OD .051 Wire . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 4 .............. 256877 .. Pin, Gear Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 5 .............. 261793 .. Pin, Clevis .250 OD X 2.500 Lg W/Groove . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 6 .............. 266830 .. Carrier, Drive Roll W/Cmpnts 24 Pitch .250 In Shaft . . . . . . . . . . . . . . . . . . 4
.. 7 .............. 260239 .. Drive Body Assy, Cast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 8 .............. 252217 .. Knob Assy, Tension Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 9 .............. 251473 .. Gear, Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 .............. 258383 .. Shaft, Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 11 .............. 276493 .. Cover, Shaft Support Auto−Continuum (Includes) . . . . . . . . . . . . . . . . . . . . 1
.. 12 .............. 279984 .. Label,Notice Wire Drive Support Cover Installation . . . . . . . . . . . . . . . . . . 1
.. 13 .............. 151828 .. Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Notes

Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2017 Miller Electric Mfg. Co. 2017−01

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TM-273473A 2017−08

Eff w/Serial No. MG140540C

Air Carbon Arc (CAC-A)

Arc Welding Power Source

350 And 500

Also Includes Auto−Continuum Drive

For product information, File: Advanced Manufacturing Systems

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage

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

1-2. Servicing Hazards

During servicing, keep everybody, especially children, away.

Auto−Continuum 350 And 500 TM-273473 Page 1

1-3. California Proposition 65 Warnings

1-4. EMF Information

TM-273473 Page 2 Auto−Continuum 350 And 500

2-1. Additional Safety Symbols And Definitions

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Keep flammables away from welding. Do not weld near flammables.

Auto−Continuum 350 and 500 TM-273473 Page 3

Do not remove or paint over (cover) the label.

After taking proper precautions as shown, connect power to unit.

Drive rolls can injure fingers.

Do not discard product (where applicable) with general waste.

TM-273473 Page 4 Auto−Continuum 350 and 500

Become trained and read the instructions before working on the

V Hazardous voltage remains on input capacitors after power is turned

Auto−Continuum 350 and 500 TM-273473 Page 5

Output Input Remote On

Off Positive Negative Voltage Input

Variable Protective Earth

Gas Metal Arc

Purge By Gas Constant Current Trigger Hold Off Read Instructions

Locked I1 Primary Current Sequence Program

Process Wire Type Gas Type Time

Trigger Hold On Trigger Hold

TM-273473 Page 6 Auto−Continuum 350 and 500

3-1. Serial Number And Rating Label Location

3-2. 350 Model Specifications

3-3. 500 Model Specifications

Auto−Continuum 350 and 500 TM−273473 Page 7

Hole Layout Dimensions

A 17-33/64 in. (445 mm) *27-3/16 in.

C 26-11/64 in. (665 mm) A

E 2-9/32 in. (58 mm) E 24-57/64 in.

3-5. Environmental Specifications

14 to 104 °F (-10 to 40°C) −4 to 131 °F (−20 to 55°C)

3-6. Static Characteristics

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3-7. Duty Cycle And Overheating

Continuous Welding 6 Minutes Welding 4 Minutes Resting

Continuous Welding 5 Minutes Welding 5 Minutes Resting

duty1 4/95 − SA-268 499-A / 268 498-A

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! Do not move or operate

Location And Airflow

4 ! Special installation may be required

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4-2. Weld Output Terminals And Selecting Cable Sizes*

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