Miller Electric XMT 4-Rack User's Manual
Contents
1. e Be sure this welding machine is installed and grounded according to this manual e If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 815 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magneti2. e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING NAINA e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Ear STATIC ESD can damage PC boards q e Putongrounded wrist strap BEFORE handling boards or paris e Use proper static proof bags and boxes to store move or ship PC boards Uy y SS MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire 43 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 N
3. black 0 0 0 eens 1 eu DT ei 602 247 WASHER flat si SAE 500 visir a ea 1 ee 602 216 WASHER lock stl split 500 222 22u sone ee ees 1 Sate POR ER 601 840 NUT brs hex 500 13 jam ees 2 KERN ee re ee 020 279 CLAMP stl cush 750dia x 281mtg hole oooooooooo 2 ste Sioa De Ota ee RER 087 318 CLAMP stl cush 1 000dia x 203mtg hole ooo ooooooooo 1 ee RR ee 010 311 CLAMP nyl 750 clamp dia x 500 wide 0 0 0 eee eee 2 en a od A in 010 145 CLAMP nyl 500 clamp dia 0 cee eee 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 OM 815 Page 16 Notes Notes Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller The Power of Blue Effective January 1 2000 Equipment with a serial number pre
4. through CB4 protects the welding power source connected to it from overload lf a Power circuit breaker opens the matching welding power source would shut down Manually reset the Power circuit breaker ST 158 333 Ref ST 155 839 Ref ST 151 269 B Figure 5 2 Circuit Breaker Locations 5 3 Troubleshooting amp WARNING LS ELECTRIC SHOCK can kill FN e Do not touch live electrical parts e Turn Off welding power sources and disconnect input power to rack before inspecting maintaining or servicing Lo l Troubleshooting to be performed only by qualified persons Table 5 1 Rack Trouble Trouble Section No weld output from any welding power Place line disconnect switch in On position sources units completely inoperative Check line fuse s and replace if needed Reset circuit breakers Check for proper input power connections to rack No weld output from one welding power Place applicable Power circuit breaker in On position source Check for proper input power connections to welding power source Check applicable welding power source according to its manual OM 815 Page 12 SECTION 6 ELECTRICAL DIAGRAM CB LI LN L2 ZO SS LOAD LS GRD 3 ho e ze 2 SS LOAD 3 mei CB4 N A OO LOAD 4 200 A SA 155 857 Figure 6 1 Circuit Diagram For Rack Control Box de OM 815 Page 13 SECTION 7 PARTS LIST Item Par No No ONO ERON
5. closest to 150 of rated input amperage of the welding power source Article 630 12 a of NEC allows fuse or circuit breaker sizing up to 200 of rated input amperage 2 Input conductor size is for insulated copper wire with 75 C rating with not more than three single current carrying conductors in a cable or raceway Table 310 16 of NEC 3 Maximum length is to prevent more than a 3 voltage drop between service entrance and input terminals of the welding power source Articles 210 19 a and 215 2 b of NEC 4 The grounding conductor shall be colored or identified as specified in the NEC Grounding conductor size for copper wire is not required to be larger than input conductor Article 250 95 of NEC Ref S 0092 G SECTION 5 MAINTENANCE amp TROUBLESHOOTING amp WARNING O ELECTRIC SHOCK can kill e Do not touch live electrical parts e Turn Off welding power sources and disconnect input power to rack before inspecting maintaining or servicing Maintenance to be performed only by qualified persons 5 1 Routine Maintenance Je 7 3 Months Turn Off all power before maintaining Replace Cracked Jad 6 Months Replace Unreadable Section Labels During Heavy Service Clean Monthly N Clean And 4 Tighten Weld Connections ST 151 267 B Figure 5 1 Maintenance Schedule OM 815 Page 11 5 2 Overload Protection 1 Power Circuit Breakers CB1 CB4 Each Power circuit breaker CB1
6. control DOX suas nie ies 1 2 CB1 4 147810 CIRCUIT BREAKER mag 3P 60A 600V 0 cee eee 4 DS ee eee ee NAMEPLATE order by model and serial number 2 Sara ee es 155 843 BLANK door opening 22 2222 ccc eee eee eens 4 sich o ee 145 743 LUG univ w scr 600V 2 14 wire 2 22 nn 4 sd ON qa dd osetia ee 148 311 DOOR access w hinge 0 ccc eee eens 4 a witha os ea 078 034 FASTENER screw sltd hd 736 lg 0 cc eee 4 Mont gt a 010855 RETAINER Screw No Z anne Den 4 E o ee 010357 NUT speed No 2 clip on type knrl na nn nananana eee 4 sop al OO A T 604 102 CONNECTOR clamp cable 1 000 0 0 cc eee 4 ae eee eee ee eee 124 245 LABEL warning electric shock can Kill o 2 i sei e tada 155 949 LABEL caution unmatched voltage can cause 00000 ee 3 ba VO eae ne 057 360 BLANK snap in nyl 1 375mtg hole 0 ccc eee 4 ae AA 155 647 a CONTROL BOX Zar ace hae eal 1 BETT gt RT 1412280 COVER box lAalde areas nen ana Rene nn awk eames A ON eee iaa 148 025 LUG univ w scr 600V 2 0 6 wire nn 1 17 DB1 147 861 DISTRIBUTION BLOCK pwr 600V 0 0 0 1 EP watering es 147 225 BRACKET mtg distribution block ooocoooooonoooooo 1 er A 084 435 SCREW cap brs hexhd 500 13 x 2 000 2 22 22n sense 1 ABRO msg aera 039 045 TERMINAL BOARD
7. 155 878 032473 155 844 151928 148851 049399 153926 151946 o 153927 sot 108 e 134327 11 155156 te Ove 147380 Sg NO es AAT O31 14 Fig7 2 Description Figure 7 1 Main Assembly COVER top GASKET lift eye BASE RETAINER hold down brkt BRACKET nut sert BRACKET hold down right WASHER flat nyl 317 ID x 500 OD x 032thk BRACKET hold down left CONTROL BOX gt Hardware is common and i not available unless listed T DE NUT speed push on type 312 stud 625 OD X 45 2 LABEL warning general precautionary 0000 cece eee eee CHAIN sash stl No 30 double loop order by ft PIN cotter hair 148dia x 2 687 lg x 625 Shaft PEG Cable h lder ect aaa wees Quantity Figure 7 1 Main Assembly ST 158 153 A 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 OM 815 Page 14 Hardware is common and not available unless listed Be ST 158 152 Figure 7 2 Control Box OM 815 Page 15 Item Dia Part No Mkgs No Description Quantity Figure 7 2 Control Box Fig 7 1 Item 14 NEATA A 155 846 COVER top
8. HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES INNO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 7 00 Owner s Record Please comp
9. OM 815 October 1994 Eff w Serial Number KC310301 E pra ps Multiprocess Welding The Power of Blue Description E Mounting Rack For Up To Four XMT 300 Welding Power Sources With AUTO LINK And Requiring 230 460 Volt Input Power XMT 4 Rack da OWNER S MANUAL Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the T RU E Bl 1 E tradition They re just as committed to providing equipment and service 6 WARRANTY ON that meets the high standards of quality and value established in 1929 Working as hard as you do This Owner s Manual is designed to help you get the most out of your every power source from Miller is backed by the most Miller products Please take time to read the Safety precautions They will hassle free warranty in the help you protect yourself against potential hazards on the worksite We ve business made installation and operation quick and easy W
10. ST 158 333 ST 151 269 B Have only qualified persons make this instal 4 Strain Relief Connector 8 Grounding Terminal lation Insert input power cord through strain relief 1 Control Box into entry hole for opened access door 2 Access Door l 5 Grounding Conductor Green Or Open access door with same number as Green With Yellow Stripe s Install grounding conductor to grounding welding power source location RR terminal 3 Welding Power Source Input Power Ppor GOpoUCIOLS Cord 7 Power Circuit Breaker Terminals Close and secure access door Install input conductors from welding power source to Power circuit breaker Figure 4 3 Welding Power Source Input Power Connections Table 4 1 Weld Cable Size Total Cable Copper Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 39 Mm OrLESS 45m 60m 70m 90m 105m 120m Welding 10 T060 60 Thru 100 Amperes Duty Cycle Duty Cycle 19 Thru 100 Duty Cycle 4 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 S 0007 D OM 815 Page 7 4 4 Common Work Connections amp WARNING A ELECTRIC SHOCK can kill ARCING can burn skin or damage Do nat touch live electrical parts electrical equipment Turn Off welding power sources by placing Power Do not a0 a of the welding cable circuit breakers in the Off position before making any connectors while we
11. ast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P For practical information on welding process applica tions and Miller products visit our website at www MillerWelds com SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING tt 12 1 3 1 4 1 5 4 1 4 2 4 3 4 4 4 5 4 6 SECTION 5 MAINTENANCE amp TROUBLESHOOTING Routine Maintenance Overload Protection 5 3 Troubleshooting SECTION 6 ELECTRICAL DIAGRAM SECTION 7 PARTSLIST 5 1 9 2 TABLE OF CONTENTS Additional Symbols For Installation Operation And Maintenance o ooo Principal Safety Standards EMF Information SECTION 2 SAFETY INFORMATION SECTION 3 SPECIFICATIONS SECTION 4 INSTALLATION Selecting A Location And Moving Rack 0 0 cece cece rr Installing Welding Power Source Onto Rack 0000 cece eee eens Welding Power Source Input Power Connections 00 0c cee eee eens Common Work Connections Paralleling Welding Power Sources For SMAW 000 cece cee nenn Conn
12. ational Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment
13. c fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 815 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 SAFETY INFORMATION mod1 1 2 93 E Read all safety messages throughout this manual E Obey all safety messages to avoid injury E Learn the meaning of WARNING and CAUTION 1 Safety Alert Symbol 2 Signal Word WARNING means possible death or serious injury can happen CAUTION means possible minor ELECTRIC SHOCK can kill injury or equipment damage can O Do not touch live electrical parts O Keep away from moving parts happen O Disconnect input power before O Keep all panels and covers closed Statement Of Hazard And Re installing or servicing when operating sult Safety Instructions To Avoid Hazard Hazar
14. cables connect to iso Ma lated terminal negative weld HT output cables go to electrode Com mon weld output cable is positive UL ST 155 335 Ref ST 154 540 A Figure 4 4 Common Work Connections OM 815 Page 8 4 5 Paralleling Welding Power Sources For SMAW amp WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Turn Off welding power sources by placing Power circuit breakers in the Off position before making any weld output connections Do not connect welding output of different polarities to the same structure See ANSI Z49 1 and OSHA Title 29 Chapter XVII Part 1910 Subpart Q addresses at beginning of manual Do not handle or come in contact with two live electrodes at the same time UNDERSIZED WELDING CABLES can cause fire O Use single cables of adequate capacity to carry the total combined amperage of the paralleled welding power sources Im Pe Pat Securely cover connection with proper insulating material IL ARCING can burn skin or damage electrical equipment e Do not change position of the welding cable connectors while welding e Be sure the connectors are secure in receptacles before welding INADEQUATE WORK CABLE CONNECTIONS can cause serious damage to input power service and create a hazardous condition e Connect an electrical cable of adequate size between the isolated terminal and the workpiece whenever any weldin
15. d Symbol If Available r Safety Banner 3 READ SAFETY BLOCKS at start of amp WARNING SW ef Section 3 1 before proceeding Read safety blocks for each sym bol shown 7 NOTE Turn Off switch when using high frequency Special instructions for best oper ation not related to safety Figure 2 1 Safety Information SECTION 3 SPECIFICATIONS Table 3 1 Rack Overall Dimensions Height 48 5 8 in 1 23 m Width 63 in 1 60 m Depth 40 in 1 02 m Required Input Power 230 Or 460 Volts AC 50 60 Hz Three Phase Weight Net 850 Ib 385 6 kg Ship 860 Ib 390 1 kg Required Welding Power Source 300 Amp XMT With AUTO LINK Requiring 230 Or 460 Volts Input Power Capacity 4 Welding Power Sources Maximum OM 815 Page 5 SECTION 4 INSTALLATION 4 1 4 2 OM 815 Page 6 Selecting A Location And Moving Rack amp WARNING ELECTRIC SHOCK can kill e Do not touch live electrical parts e Disconnect input power conductors from de energized supply line BEFORE moving rack FIRE OR EXPLOSION can result from placing unit on over or near com bustible surfaces e Do not locate unit on over or near combustible surfaces e Do not install unit near flammables FUMES can be hazardous LACK OF FRESH AIR AND PROPER VEN TILATION can be harmful Do not breathe welding fumes Place unit only where there is a good fresh air supply and proper ventilation FALLING EQUIPMENT can cause se
16. ecting Input Power To RACK nee Soe wont WARRANTY SVIMDOW USAGE atari alias do ds s nern dg das Are Welding azar ii dr Roo a o oa 0 CON OD SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ds A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols 7 Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away TEN ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly ins
17. face of LA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and outp
18. g power sources are connected to the isolated terminal Set the Amperage Voltage control on all paralleled welding power sources to the same value The iso lated terminal may be used as a common connection point if no other connections are made to it The procedure shown is for Electrode Positive welding connections 1 Weld Output Cables Determine cable sizes according to welding power source Owner s Manual Cables must reach cable connection point Cables con nected together must be the same polarity 2 Connection Point Cover with proper insulating material after making connections 3 Terminal Lugs Use lugs of proper amperage capacity and hole size for connec tion 4 Common Weld Output Cable Cable must be able to carry com bined weld output of all welding power sources connected in paral lel Use Table 4 1 to select proper cable size For Electrode Negative reverse cable connections Positive weld output cables connect to work negative weld output cables go to electrode ST 158 334 Ref ST 154 540 A Figure 4 5 Paralleling Welding Power Sources For SMAW OM 815 Page 9 4 6 Connecting Input Power To Rack amp WARNING Do ELECTRIC SHOCK can kill Do not touch live electrical parts e Turn Off welding power sources before inspecting or installing rack Have only qualified persons install rack O Installation must meet National Electrical Code and all other codes swar
19. he welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories
20. ith Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a REGISTERED QUALITY SYSTEM Troubleshooting section that will help you Miller is the first welding figure out what the problem is The parts list equipment manufacturer in SS A to be ae will then help you to decide which exact part the ISO 9001 Quality System you may need to fix the problem Warranty and alan dara service information for your particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Miller The Power of Blue Call 1 800 4 A MILLER for your local Miller distributor Your distributor gives you Service You always get the fast reliable response you need Most replacement paris can be in your hands in 24 hours Support Need f
21. lding weld output connections 0 Be sure the connectors are secure in receptacles before welding Do not connect welding output of different polarities to the same structure INADEQUATE WORK CABLE See ANSI Z49 1 and OSHA Title 29 Chapter XVII CONNECTIONS can cause serious Part 1910 Subpart Q addresses at beginning of damage to input power service and manual create a hazardous condition Do not handle or come in contact with two live e Connect an electrical cable of adequate size electrodes at the same time between the isolated terminal and the workpiece whenever any welding power sources are connected to the isolated terminal The following procedure is for Electrode Positive welding connections 1 Positive Weld Output Cables Determine cable lengths and sizes according to welding power source Owner s Manual 2 Isolated Terminal 3 Negative Weld Output Cables Determine cable sizes according to welding power source Owner s Manual Cable must reach from negative output receptacle to isolated terminal 4 Common Negative Weld Output Cable Cable must be able to carry com bined weld output of all welding power sources using common work connections Use Table 4 1 to se lect proper cable size 5 Terminal Lugs Use lugs of proper amperage ca pacity and hole size for connecting pp to isolated terminal For Electrode Negative reverse Ku 3 cable connections Positive weld output
22. lete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment 2000 Miller Electric Mfg Co 6 00 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller The Power of Blue
23. ls means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and ga
24. n3 1 2 93 Have only qualified persons make this installation 1 Rear Control Box Center 2 Access Panel Remove access panel 3 Line Disconnect Device Of Proper Rating 4 Input Conductors 5 Grounding Conductor Select size and length using Table 4 2 Conductors must be able to carry the combined amper age draw of all welding power sources mounted on the rack Con ductor insulation must comply with national state and local electrical codes Use lugs of proper amper age capacity and correct hole size 6 User Supplied Strain Relief Connector Insert conductors through strain relief 7 Input Terminal Block 8 Line Terminals 9 Ground Terminal Connect grounding conductor to ground terminal first Then connect input conductors to line terminals Reinstall access panel Install grounding conductor and in put conductors in conduit or equiv alent to deenergized line discon nect device Connect grounding conductor first then line input conductors Be sure grounding conductor goes to an earth ground 10 Overcurrent Protection Select type and size using Table 4 2 Install into deenergized line disconnect device fused disconnect switch shown ST 151 270 C Figure 4 6 Input Power Connections OM 815 Page 10 Table 4 2 Electrical Service Requirements These values are calculated from the 1993 edition of the National Electrical Code NEC 1 Recommendedfuse or circuit breaker size is that
25. ng electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding a FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 815 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of t
26. ormal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED
27. rious personal injury and equipment damage Move unit with crane or fork lift vehicle of adequate capacity swarn11 1 3 93 1 Lifting Eye Use lifting eye to move unit 2 Lifting Forks If using lifting forks be sure forks are fully inserted ST 158 366 Figure 4 1 Location And Movement Of Rack Installing Welding Power Source Onto Rack As Shipped 1 Bracket Remove user supplied bolt or lock if applicable 2 Securing Bolts Loosen 3 Front Bracket Swing end near rack center away from rack 4 Rear Bracket 5 Securing Bracket Place welding power source on rack so rear is against rear bracket and securing bracket is centered between welding power source feet Swing front bracket back into position Tighten securing bolts Reinstall user supplied bolt or lock if applicable 6 Weld Cable Hanger ST 158 332 S 0548 ST 151 268 A Figure 4 2 Welding Power Source Installation 4 3 Welding Power Source Input Power Connections amp WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Turn Off welding power source and disconnect input power to rack before inspecting or installing Have only qualified persons install unit Installation must meet National Electrical Code and all other codes swarn3 1 2 93 When installing conductors from the welding power source torque the Power circuit breaker terminals and grounding terminal to 40 in lbs 4 5 N m Tools Needed E p
28. rriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection f WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causi
29. ses If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 815 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays He burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or ba
30. talled or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som _nd_5 97 This group of symbo
31. ut rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to n
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