Miller Electric Inverter Rack User's Manual
Contents
1. Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 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 committees judgment has not demonstrated that exposure to power frequency electric and magnetic 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 818 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standar2. Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling STATIC ESD can damage PC boards 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 Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f 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 ke
3. 353 2220 site Web www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiquespendant le soudage ou le coupage OM 818 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail res pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulate
4. ment l AWS F4 1 voir les normes de s curit Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in cendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu f vent blesser les yeux e Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures risquent de projeter du laitier e Porter des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 818 Page 6 LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de 79 non utilisation e Veiller toujours bien ventiler les espaces confin s ou porter un respira teur adduction d air agr
5. que possible par ex terre Veiller souder une distance de 100 metres de tout quipement lectronique sensible Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel En cas d interf rences apr s ex cution des directives pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 818 Page 7 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 telephone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection Association P O Box 9101 1 Batte
6. Conductor Size In AWG Kcmil 6 6 8 Reference 1996 National Electrical Code NEC S 0092J 3 11 Electrical Service Guide For XMT 304 EX 300 6 Racks Input Voltage 230 460 575 pee ee Standard Fuse Or Circuit Breaker Rating In 200 175 125 Min Input Conductor Size In AWG Kcmil 1 0 2 4 Max Recommended Input Conductor Length In Feet Meters 215 66 451 137 467 142 Min Grounding Conductor Size In AWG Kcmil 4 6 6 Reference 1996 National Electrical Code NEC S 0092J 3 12 Electrical Service Guide For XMT 456 Invision 456 Racks Customer Installed Only Input Voltage 460 575 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 200 175 Min Input Conductor Size In AWG Kcmil 2 2 Max Recommended Input Conductor Length In Feet Meters 210 64 451 137 Min Grounding Conductor Size In AWG Kcmil 6 8 Due to current demandas a rack containing XMT Invisions 456 requiring 230 460 volt input power must be connected to 460 volt input power only Reference 1996 National Electrical Code NEC S 0092J OM 818 Page 17 SECTION 4 MAINTENANCE amp TROUBLESHOOTING 4 1 Routine Maintenance S E Disconnect power before maintaining 7 Maintain more often during severe conditions 3 Months Replace 2 Repair Or umso AKT tA fepe nreadable d Labels D Cables Replace Cracked Torch Body Repair Or Replace Cracked Cables A
7. Invision 456 Models Mounting Hole Pattern For XMT 304 EX 300 Models Both Shelves Mounting Hole Pattern For XMT 456 Invision 456 Models Both Shelves For XMT 304 EX 300 Models Only Location of mounting holes in bottom of base both sides For XMT 456 Invision 456 Models Only Holes 1 And 4 Holes 5 And 6 Holes 7 And 10 Have only qualified persons make this installation A Turn Off welding power sources before inspecting or installing rack For XMT 304 EX 300 Models 1 Welding Power Source Position welding power source onto rack shelf so threaded holes in feet are over correct holes in shelf on rack see illustration Welding power source front panel should face side of rack with isolated ter minal on base as shown 2 Securing Bolts And Hardware Install supplied bolts through rack shelf into welding power source feet and tighten For XMT 456 and Invision 456 Models 1 Welding Power Source Position welding power source onto rack shelf so holes in base of welder align with correct holes in shelf on rack see illustration Welding power source front panel should face side of rack with iso lated terminal on base as shown S The factory supplied mount ing hardware is for XMT 304 EX 300 models only Do not attempt to use this hard ware when installing an XMT 456 or Invision 456 onto rack Install user supplied 1 4 in mount ing bolt through holes in welding power source base and ra
8. LES PIECES CHAUDES peuvent cau ser des br lures graves e Ne pas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu lateurs cardiaques e Les personnes qui portent un stimulateur cardiaque doivent se tenir distance e Ils doivent consulter leur m decin avant de s appro cher d un lieu o on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de certains processus et quipements peut affecter l ouie e Porter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES endommag es peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais poser une torche de soudage sur une bouteille
9. Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks 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 6 Months Batteries 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s 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 normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 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 Equipmentthat has been modified by any p
10. YEL de FB2 EST F5 HEH oo LES T CAN OR E CNE o FB3 HF H F8 HEE 3 IR IES il G GEN OR CRN VEL FB4 Fo H Het lt LOAD 4 LIES H GAN OR GAN YEL 184 139 B Figure 5 3 Circuit Diagram For Control Panel In Racks Requiring 460 575 Volt Input Power For 1 4 XMT 304 Models rBl 1 1 gt _2_44 Fi H L2 gt r LF JH 3 5 O RD L EN CND EN OR GAM OR ES CAE rh 6E Br Ol F4 ii T DORIA F7 _ ES i10AD 3 F6 CEN OR LES zi dh GAN VEL Ep co i CEN OR pire 179 GRN YEL ral 4 1 F10 IL F11 E LOAD 4 F12 Q GEN OF Ee GENI YEL S e F13 n LOAD 5 F15 o oh RAS GEM YEL eke esc F16 E oa 6 Fe H GRN QR x GAW YEL 184 140 B Figure 5 4 Circuit Diagram For Control Panel In Racks Requiring 460 575 Volt Input Power For 1 6 XMT 304 EX 300 Models And Racks Requiring 575 Volt Input Power For 1 4 XMT 456 Invision 456 Models OM 818 Page 21 SECTION 6 PARTS LIST Part NO Description Quantity 4 Pack 6Pack 4Pack 6 Pack 230 460 230 460 460 575 460 575 2222581099 10 x FOUR Hack yin ts tenn Sh nce ie ee tread cnn V rat a ote ss ee es dia cl 183699 Label Warning Do Not Stack Rack 2 ae EEE gt vw 184327 Label Warning General Precautionary Den ae Nr id t 199 921 3 Bracke NO SUd Sartre area T a aaa d 41 039 045 a Terminal Ba Baek vertan teen he dL sem d 1 1
11. de gaz e Ne jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N utiliser que les bouteilles de gaz protecteur r gulateurs tuyaux et raccords ad quats pour l application envisag e les maintenir en bon tat ainsi que les pi ces connexes D tourner la t te lorsqu on ouvre la soupape d une bouteille Laisser le capuchon protecteur sur la soupape sauf en cas d utilisa tion ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz compri m les quipements associ s et les publications P 1 de la CGA mentionn es dans les normes de s curit 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e N utiliser que Tanneau de levage pour lever l ap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Si
12. 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 output 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 Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder
13. on utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil Lamm T di L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L QUIPEMENT rid e Pr voir une p riode de refroidissement respec wd ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage e Ne pas obstruer les orifices ou filtrer l alimentation en air du poste 2 2 LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s I UN ASS e Mettre un bracelet antistatique AVANT de mani puler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprim s LES PIECES MOBILES peuvent cau ser des blessures e Se tenir l cart des pi ces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage LES ORGANES MOBILES peuvent causer des blessures e Se tenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes panneaux recouvrem
14. 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 _ 8 03 This group of symbols 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 f earth grounding of the workpiece is required ground it directly with a separate 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 disch
15. 99 741 Circuit Breaker Mag 3p 50a 480vac 4 6 199 795 Fuse Crtg 30A 600V Fast Action 12 18 183912 Holder Fuse Crtg 30A 600V 3 Fuses 4 6 183 836 Distribution Blk Power 600v Black 285amp lower RH corner 1 1 Eod eae l 183 837 Block Terminal upper RH corner 1 1 mu A 185 981 Distribution Box W Holes 1 1 zi ds sx 183 698 Label Warning Electric Shock Can Kill Close Door T sine d le ee 155949 Label Caution Unmatched Voltage Can Cause Harm Etc S Eo EE 152684 Label Caution Incorrect Voltage Can Damage Etc 2 vas xw id uie 604 102 Conn Clamp Cable 1 000 4 6 E 2356 182445 Nut Conduit 1 000 Npt Pld 1 730 Od X 200 Thk 4 6 D MEINES 183167 Conn Clamp Cable 2 000 1 1 Lena 19938942 Galen DOO 2 MU t UR RAR ae AR e eo e AD on 1 1 AME 227505 583 2 Gatch Spr Loaded Door unse nenn e cused ar ea a ae Ths carats Uo pe 183914 Blank Snap in Nyl 1 250 Mtg Hole Black EEE EEE p lid 079 558 Screw 500 13x4 00 Hex Hd pln Stl Pld Full Thread lee ditto Me token l 601880 Nut 500 13 75hex 31h Stl Pld 22222 eeeeeeenn nn S A
16. AINE 602 247 Washer Flat 531idx1 0620dx 095t Stl Pld Ansi 500 dug xod E iae 601879 Nut 500 13 75hex 44h Stl Pld 1 B T E 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 818 Page 22 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 Q Miller Effective January 1 2004 Equipment with a serial number preface of LE 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
17. Cette proc dure pr sente des risques identifi s par les symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc Les symboles ci apr s sont utilis s tout au long du pr sent manuel pour attirer l attention sur les dangers potentiels et les identifier Lorsqu on voit un symbole faire preuve de vigilance et suivre les directives mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apres ne font que r sumer le contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants rm LES D CHARGES LECTRIQUES e peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement sous tension En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr
18. E OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall 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 e Use equipment of adequate capacity to lift and support unit e lfusing lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 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 m 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp
19. OM 818 183 577G m October 2004 Miller gt an Multiprocess Welding Description G EJ Inverter Rack Ll 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 tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir RU E BI U El ZA eem 7 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick hassle free warranty in the l business and easy With Miller you can count on years MI 00012000 of reliable service with proper maintenance And N for some reason the unit needs repair QUALITY SYSTEM there
20. S CURIT A LIRE AVANT UTILISATION 5 2 1 Signification des symboles 29 3 o uico me hod doa ek 5 2 2 Dangers relatifs au soudage A Tate o5 ox heh pb a 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de s curit e 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 INSTALEATION x 00 0 0 maman mania Rata aaa kr a a ae a 9 3 1 Specifications For Racks Used With XMT 304 EX 300 Models 9 3 2 Specifications For Racks Used With Invision 456 Or XMT 456 Models Gustomer installed Only Nahas 33 owed ea Haaren Regie FO axes iE weeds 9 9 9 elecundg A EOGalOD uiid Me ard doa E oo se See pha De bete ru D uote u sia Se eae ais gas 10 3 4 Installing Welding Power Source Onto Rack n 11 3 5 Welding Power Source Input Power Connections ene 12 3 0 Selecting Gable SIZES gitara rer Ia rE L A ED ERRARE BSEC NNUS EUM 13 3 7 Common Work Connections lt 9 SE S repenre cee eee hne 14 3 8 Paralleling Welding Power Sources For SMAW 15 3 9 Connecting Input Power To Rack nns 16 3 10 Electrical Service Guide For XMT 304 4 Racks eres 17 3 11 Electrical Service Guide For XMT 304 EX 300 6 Racks 17 3 12 Electrical Serv
21. 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 6 04 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City otate Zip For Service Call 1 800 4 A Mil
22. arge 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 gases If ventilation is poor use an approved air supplied respirator Head 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 818 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce inte
23. arty 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 HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO 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
24. ations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irri tants e Ne pas souder de m taux munis d un rev tement tels que la t le d acier galvanis e plomb e ou cadmi e moins que le rev tement n ait t enlev dans la zone de soudage que l endroit soit bien venti l et si n cessaire porter un respirateur adduction d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques lorsqu on les soude OM 818 Page 5 LES RAYONS DE L ARC peuvent cau ser des br lures oculaires et cuta n es Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage ou pour re garder voir les normes de s curit ANSI Z49 1 et Z87 1 Porter des lunettes de s curit crans lat raux sous le masque Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit I r l
25. ck shelf and tighten user supplied hard ware to secure in place Mounting Shelves ST 801 192 ST 801 696 ST 801 698 802 260 802 537 OM 818 Page 11 Side View Tools Needed amp B 3 Disconnect input power to rack before working on wiring for any welding power source Have only qualified persons make this instal lation 1 Control Box Open access door on front of control box 2 Strain Relief Connector 3 Welding Power Source Input Power Cord Each welding power source location on the OM 818 Page 12 3 5 Welding Power Source Input Power Connections DO Hin HD 618 0 mia 0 alp p mia 9 0 rack is numbered The numbers on the con trol box access door refer to the similarly lo cated strain relief connectors and circuit breakers inside the control box Insert power cord into strain relief with number matching location of welding power source on rack 4 Grounding Conductor Green Or Green With Yellow Stripe s 5 Grounding Terminal Install grounding conductor to grounding terminal Ref ST 801 703 ST 801 699 6 Input Conductors 7 Power Circuit Breaker Terminals 7 When installing conductors from the welding power source torque the Power circuit breaker terminals and grounding terminal to 40 in Ibs 4 5 N m Install input conductors from welding power source to Power circuit breaker nearest entry for input conductors Tighten strain relief connector Close and se cure acc
26. create a hazardous condition Connect an electrical cable of adequate size be tween the isolated terminal and the workpiece whenever the isolated ter minal is used Set the Amperage Voltage control on all par alleled welding power sources to the same value The isolated terminal may be used as a common connection point if no other con nections are made to it The procedure shown is for Electrode Posi tive welding connections 1 Weld Output Cables ST 801 701 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 connection 4 Common Weld Output Cable Cable must be able to carry combined weld output of all welding power sources con nected in parallel Use Section 3 6 to select proper cable size For Electrode Negative reverse cable con nections Positive weld output cables con nect to work negative weld output cables go to electrode OM 818 Page 15 3 9 Connecting Input Power To Rack IN 2222777777 SI S191 KAS c M x ag as IL 3 IS A E OM 818 Page 16 ET S ST Have only qualified persons make this installation Turn Off welding power sources before inspec
27. d Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keepcables 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 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles ds ldentifie un message de s curit particulier Signifie Mise en garde Faire preuve de vigilance
28. ents et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences e Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation Si la Federal Communications Commission signale des interf ren ces arr ter imm diatement l appareil Faire r guli rement contr ler et entretenir l installation Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn tique peut causer des interf rences avec l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possible les grouper et les poser aussi bas
29. ep 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 e Be sure this welding machine is installed and grounded according to this manual e lf 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 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 818 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org
30. ess door 3 6 Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual 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 Total Cable Copper Length In Weld Circuit Not Exceeding EHE MF EE XE i 60 _ o Amperes Duty Cycle Duty Cycle 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 700 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 900 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 4 4 0 4 4 0 1000 2 2 0 2 3 0 2 4 0 3 3 0 4 3 0 4 4 0 1250 2 3 0 2 4 0 3 3 0 4 3 0 4 4 0 1500 2 4 0 3 3 0 3 4 0 4 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a cu
31. ice Guide For XMT 456 Invision 456 Racks Customer Installed Only 17 SECTION 4 MAINTENANCE amp TROUBLESHOOTING 18 4 1 Rouline Mainlfenanee su xia ses uo E eX ESO ERE RO Res EI ER P ea I headed 18 4 2 Ovelload PrOleelobreudnedt d ex td EI Renner ate Md 19 49 IR STRIS Tale e s ce dp S Or Sect E podes df ied ted e aee d ded ee a oxi ier E audes 19 SECTION 5 ELECTRICAL DIAGRAMS eeeeleee enhn hh hh nn 20 SECTION 6 PARTS LIST ua mn u ea owadutsquu vdd uasa a a 22 OPTIONS AND ACCESSORIES WARRANTY 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 C7 Means Note not safety related 1 2 Arc Welding Hazards Thesymbols 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 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away L
32. ler 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 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 Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2004 Miller Electric Mfg Co 1 04 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 GQ Miller
33. nd Cords 2 Clean And Tighten Weld Connections Clean And Tighten Connections To Isolated Terminal OM 818 Page 18 4 2 Overload Protection Control Box Power Circuit Breaker In Racks For 230 460 Volt XMT 304 EX 300 Models And 230 460 Volt XMT 456 Invision 456 Models Location Of 3 Phase Fuse Block 460 575 Volt XMT 304 Models And 575 Volt XMT 456 Invision 456 Models Each Power circuit breaker or fuse block protects the welding power source connected to it from overload If a Power circuit breaker opens the matching welding power source shuts down Manually reset the Power circuit breaker 3 3 Phase Fuse Block In Racks For 460 575 Volt XMT 304 Models And 575 Volt XMT 456 Invision 456 Models okk Jolo 4 Fuses G D Bio B DE o PE o OR o ER O D S If fuse s in fuse block opens the O lolo O c SEC matching welding power source shuts down To check fuse block place line disconnect switch in Off position and open hinged fuse hold er on applicable fuse block to ac cess fuses Check fuses and re place if necessary ST 801 703 ST 801 767 Trouble Remedy No weld output from any welding Place line disconnect switch in On position see Section 3 9 power sources units completely inoperative Check and replace line fuse s if necessary or reset circuit breakers see Section 3 9 Check for proper input power connections to rack see Sec
34. nse visible and invisible ultraviolet and infrared rays that can 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 Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers 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 fa WELDING can cause fire or explosion E 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
35. onnecter plus d une lectrode ou plus d un cable de masse un m me terminal de sortie Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz dont l inhalation peut tre dangereuse pour la sant e Se tenir distance des fum es et ne pas les inhaler e l int rieur ventiler la zone et ou utiliser un dispositif d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est insuffisante utiliser un respirateur a adduction d air agr e Lire les fiches techniques de sant s curit FTSS et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Netravailler dans un espace clos que s il est bien ventil ou porter un respirateur adduction d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxyg ne et causer des l sions ou des accidents mortels S assurer que l air est respira ble e Ne pas souder proximit d op r
36. put of all welding power sources using common work connections Use Section 3 6 to select proper cable size 5 Terminal Lugs Use lugs of proper amperage capacity and hole size for connecting to isolated terminal Isolated terminal is 1 2 in 12 7 mm in diameter For Electrode Negative reverse cable con nections Positive weld output cables connect to isolated terminal negative weld output cables go to electrode Common weld output cable is positive 3 8 Paralleling Welding Power Sources For SMAW VON Be a Securely cover connection with proper material 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 dif ferent 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 Use single cables of adequate capacity to carry the total combined amperage of the paralleled welding power sources ARCING can burn skin or damage electrical equipment Do not change insulating position of the welding cable connec tors while welding Be sure the connectors are secure in receptacles before welding INADEQUATE WORK CABLE CON NECTIONS can cause serious dam age to input power service and
37. r 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 installed 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
38. r 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 the 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 Head 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 FIR
39. rre ad quat et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm diatement s il est en dommag tout c ble d nud peut causer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre insuffisant ou mal piss s e Ne pas s enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un Cable distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode d une autre machine som fre 8 03 Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance Il y a des dangers li s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de connaitre les me sures prendre pour viter tout danger e N utiliser que du mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de facon obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e Ne pas c
40. rrent density of at least 300 circular mils per ampere S 0007 D OM 818 Page 13 N N NZ A 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 dif ferent polarities to the same struc ture 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 ARCING can burn skin or damage electrical equipment Do not change position of the welding cable connec tors while welding Be sure the connectors are secure in receptacles before welding OM 818 Page 14 3 7 Common Work Connections INADEQUATE WORK CABLE CON NECTIONS can cause serious dam age to input power service and create a hazardous condition Connect an electrical cable of adequate size be tween the isolated terminal and the workpiece whenever the isolated ter minal is used 1 Positive Weld Output Cables Determine cable lengths and sizes accord ing 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 ST 801 700 reach from negative output receptacle to isolated terminal 4 Common Negative Weld Output Cable Cable must be able to carry combined weld out
41. ry March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Web www csa interna tional org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312
42. s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in neus Ate be reales exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided 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 Mill Hier Mil_Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Ths Symbol US Te ne est mee WE QR So br OE RE Peta eee See om as i ER wens 1 1 27 Are Welding Hazards a ack shade kd nee ECT en du aee dci mc e Roe s bac tn OT icu ne Aa ode eee 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 Galifornia Proposition 65 Warnings ss ux iex E m Ree wx DERE REESE NE irait bros 3 1 5 Prncipal Safety Standards seapea noas a nr eb dictt lod ases delet debut den duin Debt aiat rire 4 1 62 EMEB IDIOUIUSORI dera a ores A atte ta atus E R asit e busca deer E d 4 SECTION 2 CONSIGNES DE
43. sente un danger e Ne jamais toucher aux pi ces lectriques sous tension e Porter des gants et des v tements de protection secs et exempts de trous e GSisoler de la piece et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre e Ne pas se servir d une source de courant alternatif dans les zones humi des les endroits confin s ou l o on risque de tomber e Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige e Si l utilisation d une source de courant alternatif s av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil Couper tiqueter l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor mes de s curit e Installer et mettre la terre correctement l appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la te
44. t LE SOUDAGE peut causer un incen TER die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles les pi ces chaudes et les quipements chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger Se prot ger et prot ger les tiers de la projection d tincelles et de m tal chaud Ne pas souder un endroit o des tincelles peuvent tomber sur des substances inflammables Placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections agr es Des tincelles et des mati res en fusion peuvent facilement passer m me par des fissures et des ouvertures de petites dimensions Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s conform
45. 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 causing 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 ws FLYING METAL can injure eyes e Nelding 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 818 Page 2 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 Pacemaker wearers keep away e Wearers should consult thei
46. ting or installing rack 1 Control Box Open access door 2 Line Disconnect Device Of Proper Rating 3 Input Conductors 4 Grounding Conductor Select size and length using Sec tion 3 10 or 3 11 Conductors must be able to carry the combined am perage draw of all welding power sources mounted on the rack Con ductor insulation must comply with national state and local electrical codes 5 Strain Relief Connector Insert conductors through strain relief 6 Input Terminal Block 7 Line Terminals 8 Ground Terminal Connect grounding conductor to ground terminal first Then connect input conductors to line terminals Close control box access door 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 9 Overcurrent Protection Select type and size using Section 3 10 or 3 11 Install into deen ergized line disconnect device fused disconnect switch shown ST 801 702 Ref ST 801 703 3 10 Electrical Service Guide For XMT 304 4 Racks Input Voltage 230 460 575 Max Recommended Standard Fuse Or Circuit Breaker Rating In 200 110 90 Amperes Min Input Conductor Size In AWG Kcmil 2 6 8 Max Recommended Input Conductor Length In Feet Meters 210 64 301 92 300 91 Min Grounding
47. tion 3 9 No weld output from one welding pow For racks containing Power circuit breakers place applicable Power circuit breaker in On position for er source racks containing fuse blocks check fuses in applicable fuse block see Section 4 2 Check for proper input power connections to welding power source see Section 3 5 Check applicable welding power source according to its Owner s Manual OM 818 Page 19 SECTION 5 ELECTRICAL DIAGRAMS CB1 L1 Z AK ZTA LOAD 1 Lane o 2 GAN OR ern E 2 zx T EE DR us RP 283 RET C Lanka o CB4 ZEN MIC PK LOAD 4 GAN OR GAN YEL 184 000 B Figure 5 1 Circuit Diagram For Control Panel In Racks Requiring 230 460 Volt Input Power For 1 4 XMT 304 Models LOAD 2 CB1 L1 7 ALK Fe L2 ras WIHT ha L3 e AED ar IC on GAN OR GAN OR oe ccce Ne CAN TEL SE LTC Hy N e LOAD 2 GAN OR IG GIAI YEL CB3 III Hy E p LOAD 3 CAN OR WO 2 GAN VEL CB4 TX A ox a ET LOAD 4 CAN OR n SAM CAMI YEL CB5 TX x E ES ie CAN OR a CANS YEL 4 CB6 LTO roo 2l LOAD 6 CAN Ok 3 184 138 B CEM YEL Figure 5 2 Circuit Diagram For Control Panel In Racks Requiring 230 460 Volt Input Power For 1 6 XMT 304 EX 300 Models And Racks Requiring 460 Volt Input Power For 1 4 XMT 456 Invision 456 Models OM 818 Page 20 FB1 1 EE E H 2 M FZ H p m E LOAD 1 L3 leo Bes a E GND CAPE GRN
48. urs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 INSTALLATION 3 1 Specifications For Racks Used With XMT 304 EX 300 Models Input Power Required Welding Power Capacity To Rack Source 4 Rack 6 Rack I C oe v Er Poner Save BOERS TRS apar 1 ovea Poner souco P E a d EX 300 SPA 575 Volt N A 1 6 Welding Power Sources 3 2 Specifications For Racks Used With Invision 456 Or XMT 456 Models Customer Installed Only Input Power i To Rack Required Welding Power Source Capacity 460 Volts AC XMT 456 Or Invision 456 Models 60 Hz Three Phas Requiring 230 460 Volt Input Power Operated On 1 4 Welding Power Sources 460 Volt Input Power Only 575 Volts AC XMT 456 Or Invision 456 60 Hz Three Phase Requiring 575 Volt Input Power 1 4 Welding Power Sources OM 818 Page 9 3 3 Selecting A Location Dimensions And Weight 256 lb 116 kg A 34 3 8 in 873 mm Movement OM 818 Page 10 7 ft 2 1 m minimum length 7 ft 2 1 m minimum length 1 Lifting Eyes Use lifting eye to move unit 2 Lifting Forks If using lifting forks be sure forks are fully inserted loc 2 3 96 ST 801 697 3 4 Installing Welding Power Source Onto Rack For XMT 304 EX 300 And XMT 456
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