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Miller Electric Axcess 450 Welder User Manual

1. PE ao 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 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 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 ou
2. eus 1 brise OBT ius 083432 Supplementary Protector Man Reset 1P 10A 250VAC Frict 1 T OBZ 093995 Supplementary Protector Man Reset 1P 15A 250VAC Frict 1 8 PR 196814 Receptacle w Leads 115V Duplex 1 niu durs POTZ cubes 209676 Circuit Card Assy E 8top 1 Tro EE 115440 Stand off no 6 32 x 687 lg 250 hex al fem 4 uu Mc 212764 Plug AssyRear 1 OPTIONAL 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 220 389 Page 42 Hardware is common and not available unless listed m Ref 803 424 B Figure 11 5 Front Panel Assembly Item Dia Part No Mkgs No Description Quantity Figure 11 5 Front Panel Assembly Fig 11 1 Item 14 D es o PNE 207456 Switch Rotary 2 Posn 1P 40A 600VAC 90Deg 1 o4 207895 Insulator Switch Power 1 no RUPEE 211475 xc Plate front panel s buses madeleine ERA RON E bee des 1 ess PO sacs 208071 Circuit Card Assy ISO COMM
3. 1 ar FM 196313 Fan Muffin 115V 50 60 Hz 3000 Rpm 6 378 Mtg Holes 2 O 4 06 07 68 aes 206678 Capacior ASSY cesa ie bea baa ead oe AA ae de 3 213102 Choke Common Mode w Leads 2 NW WO EO PEE 216965 Cover Connector D sub 9 skt Female w Chain 1 ne enun et 216966 Cover Connector D sub 9 pin Male w Chain 1 HO Lo 2 RO 214664 Receptacle Common Mode Choke 1 Tuum 025248 Stand off Insul 250 20 X 1 250 Lg X 437 Thd 2 UN PHP 207897 ABUS D dts RS ete Stee MT cale UE 2 gt AE LA AE 210866 Terminal Pwr Output Black 1 Tu PPP 2104 3 Pals exis acct es dat un ttd Robo rte data des 1 219843 Label Work Sense Wordless 1 OM 220 389 Page 43 No Mkgs No Description Quantity Figure 11 5 Front Panel Assembly Continued voL NE eu E 207996 BOX LOUV R Bela de ted e ui Gods 1 MEL 196621 BOOL GONCIC a dec def sc D Rh ce mo rm 2 EE PIS ux 153902 za IGANG white lens and qb are oa aaa UC Y IRI nM xd apa 1 x d us eb tested det ein des 210496 Nameplate Front Li serbe nb Gianni 1 TONO DECRE 210865 Terminal Pwr Output Red 1
4. 1 DE pcm 223439 Insulator Circuit Card Aux Power 1 TURO MPO PED 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 E asane POA 204048 Circuit Card Assy Process Control Module 1 ES aee 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 8 210491 Panel Mtg Components Top 1 T urn 198122 Stand Off Support PC Card 250 w Post amp Lock 500 1 OPTIONAL 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 220 389 Page 41 Hardware is common and not available unless listed Ref 803 423 B Figure 11 4 Rear Panel Assembly No Mkgs No Description Quantity Figure 11 4 Rear Panel Assembly Fig 11 1 Item 8 te ees ns een eee 210474 PONG edi x isa Db e Apo OR Gt Zum Ga o fone 1 CERTO 2108562 EVS cuisinier onde 1 219929 Nameplate Rear 1 A 217297 Cover Receptacle Weatherproof Duplex Rept 1 210483 lt Bracket It
5. Status Diagnosis Off The circuit board is not on line with the network or there is no power applied to the circuit board Green The circuit board is operating normally and the on line connection is made with the network Flashing Green The circuit board is waiting for an on line connection to be made with the network Red The circuit board has encountered a communication link failure with the network Check DeviceNet cable connections Verify dip switch positions according to Sections 1 2 and 1 3 Replace circuit board if necessary B Module Status LED s The following is a module status LED LED3 on the PCM circuit board Status Diagnosis Off There is no power applied to the circuit board or the board software is not executing its functions Green The circuit board is operating normally Flashing Red The circuit board has encountered a recoverable fault Wait or cycle power to clear fault Red The circuit board has encountered an unrecoverable fault OM 220 389 Page 34 9 5 Troubleshooting Trouble Remedy No weld output completely inoperative Place line disconnect in On position see Section 4 11 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 11 Check for proper input power connections see Section 4 11 No weld output meter display on with no error displayed Check to see if the contactor indica
6. mili Turn Off inverter disconnect input power and discharge input Capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 220 389 Page 1 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 local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers 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 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 Do not weld on coated metals such as galva
7. tincelles risquent de causer un incendie loigner toute sub stance inflammable 79 Q gt gt a LES CHARGES ELECTROSTATI QUES peuvent endommager les circuits imprimes e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Nepas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande lm OM 220 389 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures ES e S abstenirde toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remetire les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS
8. READ INSTRUCTIONS e Use Testing Booklet Part No 150 853 when servicing this unit e Consult the Owner s Manual for welding safety precautions e Use only genuine replacement parts from the manufacturer For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive 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 1 Keep cables close together by twisting or taping them or using a cable cover 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 Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 220 389 Page 31 SECTION 9 TROUBLESHOOTING 9 1 Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power source 900 Volts dc can be present on the capacitor bus and disconnect input power sign
9. e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N tiliser que les pieces de rechange recom mand es par le constructeur e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e Lutilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e l nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lect
10. fal cee ot PEN 210483 lt lt Bracket IU GO iu be bx UE el Seine tiers 1 AMATUR ta 210358 Bolt eye shld thd stem 500 13 X 1 500 1 OPTIONAL 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 220 389 Page 44 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 2 Miller Effective January 1 2007 Equipment with a serial number preface of LH 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 workman
11. Amm P9 mee 8e eii p aat Tmin e l nr MTS aman m anii eniin ES E asap g nimm s su n 6 NN SAN a Ln mm gee jt L LED Am mm imm mmt s P B IIT w e e s ZEEE OW ii ET d LED4 a8 2 2 num e unis ur H Le COLE ATT CHINE E IDOC eant iH ell EE EE EE 97 a Mees BB EN 1 1 g e e ell Ba BR on ra 082 nue se si ae LS La MET Jn O CRC PE RE 1 2 pu Bra af m mma 655 5 e e 2 ee sd 28 8 gm aman es GJ gananing eens Teri 5 3 4 1 J9 5 1 67 4 216 956 Ref 803 419 9 3 Diagnostic LED s On Process Control Module PC4 LED Status Diagnosis 1 On Indicates 25 volts dc is present on process control module PC4 Off Indicates 25 volts dc is not present on process control module PC4 2 On Indicates 25 volts dc is present on process control module PC4 Off Indicates 25 volts dc is not present on process control module PC4 3 4 On See Network Status Table in Section 9 4 Off See Network Status Table in Section 9 4 OM 220 389 Page 33 9 4 Network And Module Status LED s A Network Status LED s The following is a network status LED LED4 on the PCM circuit board
12. Location A Do not stack units Beware of A Special installation may be required where gasoline or volatile tipping liquids are present see NEC Article 511 or CEC Section 20 1 Lifting Forks Use lifting forks to move unit Extend forks beyond opposite side of unit 2 Cart Use cart or similar device to move unit S 2 3 Rating Label VOLTS Use rating label to determine input AMPERES KW S power needs PHASE 4 Line Disconnect Device Locate unit near correct input power supply loc 2 3 96 Ref 803 410 B Welding Power Source Wire Feeder Gas Cylinder Gas Hose Network Feeder Cable Negative Weld Cable Workpiece 8 Work Sense Lead Recommended for Accu pulse and RMD optional 7 Positive voltage sensing lead is contained in the motor cable 9 Positive Weld Cable Vi 7 P Ref 803 410 B Ref 801 915 A OM 220 389 Page 16 4 7 Rear Panel Receptacles And Supplementary Protectors 1 115V 10 A AC Receptacle RC2 Receptacle supplies 60 Hz single phase power Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload If CB1 opens RC2 does not work CB2 protects the wirefeed motor from overload If CB2 opens the wirefeeder does not work Press button to reset breaker If breaker continue to open contact a
13. T lt lt 5 42 lt Res z S TL RC amp 11 lt 5 16 SF lt RC6 8 If lt RCB 9 i i 17 lt RC6 1 g 220 420 B OM 220 389 Page 37 SECTION 11 PARTS LIST zt D LL 5 Fig 11 2 4 Fig 11 3 NAT m B ANN Hardware is common and not available unless listed E lt C iL 15 Ref 803 856 B Figure 11 1 Main Assembly OM 220 389 Page 38 Item Dia Par No Mkgs No Description Quantity Figure 11 1 Main Assembly Meats 210492 une ation ends cate MS appe cs Mea eS bts 1 PES let 212543 Xfmr Control Toroidal 665 VAC Pri 1900 VA 60 Hz 1 dian E A 210481 Plate Mtg Toroid Xfmr 1 a 13 se TOD Tray ASSEMDIY 2 E 1 5 IM1 IM2 214597 Windtunnel w Components Fig 11 2 2 222958 Windtunnel RH w Components Fig 11 2 2 OR 198961 Panel Module Divider 2 1 Tous 180270 Contactor DEF PRP 40A 24VAC Coil W Boxlug 1 D rs een ao de Fig 11 4 Rear Panel Assembly 1 oec 22 799 Panel Side WANSUIALON X ba mee eds 2 ets 210492 BASE uis ES open made 1 ste eee
14. and wire feeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from re ceptacle or stop engine before servicing unless the procedure spe cifically requires an energized unit e Insulate yourself from ground by standing or working on dry insulat ing mats big enough to prevent contact with the ground e Do not leave live unit unattended e If this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job e When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free e Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source 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 Troubleshooting Section be fore touching any parts 79 Q gt gt gt STATIC ESD can damage PC boards 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 OM 220 389 Page 30 OM 220 389J 2007 10 safety stm 2007 04 Indicates special instructions This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instruction
15. can cause injury Keep away from moving parts such as fans e Keep away from pinch points such as drive rolls e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away from serv icing areas until consulting their doctor and the device manufacturer 8 3 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 Safety Code Section 25249 5 et seq 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 8 4 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 b
16. des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la mainte
17. green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 8 Over Current Protection Select type and size of over current protec tion using Section 4 10 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position SECTION 5 RECOMMENDED SETUP PROCEDURES 5 1 Selecting Weld Cable Sizes ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual 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 Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding N 7 d 350 ft 400 ft 150 ft 200 ft 250 ft 300 ft 100 ft 30 m or Less 45m 60m 70m 90 m 105 120 m m Weld Output Terminals Turn off power before 10 60 60 100 connecting i weld Duty Duty 10 100 Duty Cycle output terminals peres Cycle Cycle
18. of a weld cause excessive spatter and impair the quality of a weld Arc blow occurs primarily during the welding of steel or ferromagnetic metals Weld current will take the path of least resistance but not always the most direct path through the workpiece to the work lead connection The most intense magnet force will be around the arc due to a difference in resistance for the magnetic path in the base metal The work clamp connection is important and should be placed at the starting point of a weld It is recommended to have as short of an arc as possible so that there is less of an arc for the magnetic forces to control Conditions affecting the magnetic force acting on the arc vary so widely that the reference here is only about cabling connections and arc preferences Current Flow Path gt Ref 804 459 A OM 220 389 Page 24 5 5 Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A Bad Setup ND Current Flow Path eee Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder 7 Workpiece This arrangement is a bad setup due to sensing leads being directly in the current flow path of the welding arc Interaction between welding circuits will affect voltage drop in the workpiece The voltage drop Ref 804 460 A across the workpiece will not be measured correctly for the voltage feedback signal Voltage feedback to the weld
19. 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 Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association 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 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 for
20. ranges are for GMAW welding While pulse welding wire feed speed ranges may be more limited 4 2 Dimensions And Weight Hole Layout Dimensions 22 1 2 in A 17 3 32 in 434 mm B 17 3 8 in 441 mm 31 in C 19 3 32 in 485 mm 787 mm D 16 3 32 in 409 mm E 1 2in 13 mm Weight 17 3 32 in 434 mm 163 lb 74 kg Net n 180 Ib 82 kg Ship Ref 803 410 B OM 220 389 Page 14 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or OPERATION duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty WELD AMPERES 40 50 60 70 8090100 DUTY CYCLE 100 Duty Cycle At 450 Amperes 60 Duty Cycle At 580 Amperes Continuous Welding 6 Minutes Welding 4 Minutes Resting Overheating 9 01 0 Minutes Reduce Duty Cycle duty1 4 95 220 485 A 4 4 Volt Ampere Curves CV MODE Volt ampere curves show minimum and maximum voltage amperage output capabilities of unit Curves of other settings fall between curves shown This volt ampere curve represents the dynamic output of the unit with a static load va curvel 4 95 220 486 A OM 220 389 Page 15 4 5 Selecting A Location Tipping A Do not move or operate unit where it could tip
21. 0012000 of reliable service with proper maintenance And for some reason the unit needs repair QUALITY SYSTEM there 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 exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your Sysiem 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 specification 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 2 Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Ths Symbol US aeu ne nt abatement QR Ante Gees OE ae Peta See om as ak aot wens 1 122 Are Welding EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 Galifornia Proposition 65 Warnings 4 1 9 PincipalSatety Standards acier ns dd E E ARR DERRE RERS 4 1 62 Hates NT E E E E E R 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILI
22. 1 Fax 39 02 98290203 la Declares that this product Axcess di 450 conforms to the following Directives and Standards European Contact Signature Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility Directives 89 336 EEC 92 31 EEC 2004 108 EC Machinery Directives 98 37EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC CE Marking Directive 93 68 EEC Standards Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 3 2005 07 Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 Ed 1 1 2004 10 Degrees of Protection Provided By Enclosures IP Code IEC 60529 Ed 2 1 2001 02 The product technical file is maintained by the responsible Business Unit s located at the manufacturing facility dec stat 1 07 SECTION 1 SAFETY PRECAUTIONS READ USING som 2007 04 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards
23. 196514 Gasket Inductor Mounting NEC RER 196512 Bracket Inductor Mounting 196330 Heat Sink Power Module 34 E 196345 Coil Inductor Pre regulator 196588 Baffle Foam Rubber Lower TP 196365 2195 WE AS ober od wind eae D di sata qu dod qs 199136 Plugs w Leads PC2 To PC1 1 36 POT ams 218790 Circuit Card Assy Control Inverter 300A 1 OU Gia idee dede 204846 Insulator 4 OO duum cer 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 4 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 220 389 Page 40 Hardware is common and not available unless listed 7 803 422 B Figure 11 3 Top Tray Assembly Item Dia Part NO Mkgs NO Description Quantity Figure 11 3 Top Tray Assembly Fig 11 1 Item 4 tao Wh aides PO dca mee 231928 Circuit Card Assy Aux Power
24. 220200 Filter Assembly Primary Ground 1 12 HD2 182918 Transducer Current 400A Module Supply V 15V 1 13 14 185697 Circuit Card Assy Input Filter 1 jr Sea ee ee 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 E 213372 Filter Assy Secondary 2 jor Fig 11 5 Front Panel Assembly 1 227855 Kit Connectors W Washer For Power Cables Includes 1 ion 010467 Connector Clamp Cable 1 250 1 don ET c 225840 Washer Reducer 1 25 in 0 75 in 2 ES PP ih a ee ator 010916 Connector Clamp Cable 0 750 1 OPTIONAL When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Hardware is common and not available unless listed 802 955 A Figure 11 2 Windtunnel Assembly LH And RH OM 220 389 Page 39 Item Dia Part No Mkgs No Description Quantity Figure 11 2 Windtunnel Assembly LH And RH Fig 11 1 Item 6 ge 214597 Windtunne
25. Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 4 0 4 0 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 120 120 4 0 2 ea 2 0 2ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 120 2x70 2x70 4 0 2 ea 2 0 2 ea 3 0 2 ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2x95 4 0 2 ea 2 0 2ea 3 0 2ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2 95 2x120 4 0 2 ea 2 0 2ea 3 0 2ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 120 2 70 2 95 2x120 2x120 2 ea 2 0 2 3 0 2ea 4 0 3ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2 70 2x95 2x120 3x95 3x95 2 ea 2 0 2ea 3 0 2 4 0 3ea 3 0 3ea 4 0 3 ea 4 0 600 3 0 95 4 0 120 Positive Negative 2x70 2x95 2x120 3x95 3x120 3x120 i 700 4 0 120 2 ea 2 0 2ea 3 0 2ea 4 0 3 0 3ea 4 0 3ea 4 0 4 ea 4 0 Ref 803 418 B 2x70 2x95 2x120 3x95 3x120 3x120 4x120 800 4 0 120 2 ea 2 0 2ea 3 0 2 4 0 3 ea 4 0 3ea 4 0 4ea 4 0 4 ea 4 0 2x70 2x95 2x120 3x120 3x120 4x120 4x120 This chart is a general guideline and may not suit all applications If cable overheating occurs use next size larger cable Cable
26. FETY PRECAUTIONS FOR SERVICING 30 Bl Sage ure oleh ne fuste D aac ed R Gregor Re 30 B 25 OEC Ng Hazards vta ond d the ba e d avita dad Oise 30 8 3 California Proposition 65 Warnings 80 31 8 4 EMF Information decedit ar odit oe ed a a baa bh oe So heres 31 TABLE OF CONTENTS SECTION 9 TROUBLESHOOTING 7 5 239 9 s d a c ao e I a e eR s 32 9 1 Removing Cover and Measuring Input Capacitor Voltage 32 9 2 Process Control Module PC4 Diagnostic LED s 33 9 3 Diagnostic LED s On Process Control Module PC4 33 9 4 Network And Module Status LED S usse xm An ER RENAN RES 34 9S AS Sn hah Gonads ont del metre soak nero 35 SECTION 10 ELECTRICAL DIAGRAMS 4 404040 uses nnn nnn 36 SECTION IL PARIS LISTE oe 38 WARRANTY Declaration of Conformity for European Community CE Products This information is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290
27. Factory Authorized Service Agent 4 Network Wire Feeder Receptacle RC1 Use receptacle to connect network feeder cable to power source see Section 4 6 Ref 803 417 A OM 220 389 Page 17 4 8 Connecting To Weld Terminals 7 If using an electrode negative straight polarity process the volt sense lead must be connected to the work Tools Needed gt 3 4 in 19mm A Turn off power before connecting to weld output terminals A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine Determine total cable length in weld circuit both positive and negative cables combined and maximum welding amperes See Section 5 1 to select proper OM 220 389 Page 18 Do not place anything between weld cable terminal and copper bar Correct Installation cable size 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal Connect positive weld cable to Positive weld terminal and negative cable to Negative weld terminal 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal Incorrect Installation Ref 803 410 B 803 778 A 6 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the sur
28. Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT 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 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 MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating 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 physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder
29. Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa 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 U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 telephone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 220 389 Page 9 OM 220 389 Page 10 SECTION 3 DEFINITIONS 3 1 Manufacturer s Warning Label Definitions Warning Watch Ou
30. J5 PLG36 J80 PLG37 J7 PLOG amp 3 J10 PLG81 D y V RC4 1 gt Lag E STOP BOARD RC4 2 gt RC1 PLG75 REZ PLG76 RC4 PLG40 RCS PLG77 RCG6 PLG78 RE7 PL6S1 RC amp PLGSO 006060 R ZI PLG21 1 gt 15 VET 4 gt PRANCE A iSV OANGE 4 SERIAL COMMUNICATION BOARD J4 Z lt lt RCZ 4 4 2 297 lt lt RC2 3 J4 3 5 292 lt lt RO2 2 d4 45 5 29J lt RC2 1 J4 5 gt gt _24 ee RC2 5 J4 6 gt gt 492 lt lt RC2 6 PCI 3 RCZ PLGB3 ca 5 FERRITES TYP 3 PLCS SS Zi X RC1 2 TRANSMIT lt RC1 3 RECEIVE RC1 5 4COMMON RC1 7 READY TO SEND RC1 8 CLEAR TO SEND gt RO3 2 RECEIVE gt RC3 3 TRANSMIT gt RC3 5 COMMON DRC3 7 READY TO SEND gt RO3 amp CLEAR TO SEND en G1 GZ J10 3 gt J10 2 2 1 110 4 gt gt 1 256 J10 1 gt lt 2 9 Figure 10 1 Circuit Diagram For OM 220 389 Page 36 RE gt gt N ul c a z RCI 3 gt x 6 uu A RCE 2 lt 68 5 FRE PEZ gt gt INTERGONNECT BOARD RG1 PLG11 ii RCZ PLG12 RC6 PL614 RECT AUX POWER BOARD RCI FLG18 RC2 PLG19 lt RCZ 1 lt 2 5 ris NOTE POWER CABLE TO BE SUPPLIED amp INSTALLED BY CUSTOMER Welding Power Source NEGATIVE Q 4 WARNING Do not touch live electrical parts Discon
31. Min Input Conductor Size In AWG 10 Max Recommended Input Conductor Length In Feet Meters os Min Grounding Conductor Size In AWG 4 10 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 peus Operating general purpose no intentional delay fuses are UL class 5 up to and including 60 amp and UL class H 65 amp and 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 220 389 Page 19 4 11 Connecting Input Power Tools Needed 3 N 7 X N y GND PE Earth Ground sfols_ BES to filter board SIA 219 842 ground terminal 8 L 4 SB in A Turn Off welding power source and check voltage on input capacitors according to Section 9 1 before proceeding Installation must meet all National and Local Codes have only qualified persons make this installation Disconnect and lockout tagout input power before connecting input conductors from unit Make input power connections to the welding power source first A Always connect green or green yellow con
32. NS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer 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 Toreduce 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 e Be sure this welding machine is installed and grounded according to this manual e lfinterference still occurs the user must take extra measures such as moving the
33. OM 220 3894 2007 10 Processes MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding Description E3 zz Arc Welding Power Source CE Axcess 450 OWNER S MANUAL Visit our website at File Advanced Manufacturing Systems 4 www MillerWelds com ams We 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 Jj El ZA eem 04 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 A 5 88 warranty in the and easy With Miller you can count on years MI 0
34. R 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 2007 01 Owner s Record Please complete and retain with your personal records Model Name S
35. SATION 5 2 1 5yrmboles vaut dan M nd d a nd dad acte tea das a 5 2 2 Dangers relatifs au soudage larc uoa sus dise ehe Rc etica x ep dica ce sde 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 82 9 2 5 Intommatlon EME an eoru x dace Urn aded d e RC de ne dol a ie a cadit 9 SECTION S DEFINITIONS sien teehee 11 3 1 Manufacturers Warning Label Definitions 11 WEEE Label ae an ind eue 12 AN DENUN S vase de n odo dou mur c pce re deer dra bcne nd dte eis 13 3 4 Manufacturers Rating Label App A ae nl eee 13 SECTION 4 INSTALLATION eoe denied 14 Z5 CalloliS URSS rua xo ER Bev te e ta are E Se rui wae de PME eds 14 4 2 Dimensions ANG WIGHT iss ote Rv oats nx REEF Meets EU KNEE Se oes ae LORS MENS 14 4 3 Oycle And Overheating ers over Eis REESE Vir ns Debe oa ee TENES 15 4 4 MOl Ampere sers is vee veep ENTE vee ee hey oe RS ee ee 15 4 5 Selecting A LOCA
36. UOM 16 2 6 Conne cion Diagram epp onem Rind eq ERE Rend aim d KERO EERS EE 16 4 7 Rear Panel Receptacles And Supplementary Protectors 17 4 8 Connecting To Weld Terminals 882 18 4 9 Network Wire Feeder Receptacle Functions 19 4 10 Electrical Service Gude us atre acd y Rhe DEO Rea E te Re dO b d d Read uid 19 4 11 Connecting Input POWGF 2 Ein hor scies toner dress frise 20 SECTION 5 RECOMMENDED SETUP PROCEDURES 21 5 1 Selecting Weld Cable SIZ8S ss a0 12444 a puma dene mie aime meta ex SOR able E RO SOR o RC RO d 21 9 2 Welding Creu mT 22 5 3 Arranging Welding Cables To Reduce Welding Circuit Inductance 23 5 4 Using Multiple Welding Power Sources 24 5 5 Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs 25 SECTION 6 OPERATION 28 Front Panel SWwIICDeS sas nine saisies 28 SECTION 7 MAINTENANCE 2 29 s ROUNDS Maintenance le uses HE Rae dose Bone nea ASA 29 1 2 3Blowirig Outinside OF UNI roc n Heap awed ao we Dawes eau rp A Qua RD E 29 SECTION 8 SA
37. Volt Conventional may vonage Load Voltage Degree Of Rated Welding Rated No Load Voltage Average Rated Maximum Maximum Effective Supply Current Supply Current 3 4 Manufacturer s Rating Label MILLER ELECTRIC MFG CO APPLETON WI USA MADE IN a STOCK 907275 1 9s IEC 60974 1 AKORI GB 15579 1 2004 27 15 3V 600A 44V 6 X 56 60 100 wm 90 74 5 12 600 580 450 U2 44 43 365 jD v JH maxi eff U1 400 44 8 27 9 37 50 60 Hz 380 478 30 3 pase x 100 www MillerWelds com ams EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 225636 5 04 225 636 220 389 13 SECTION 4 INSTALLATION gt Appearance of actual unit may vary from unit shown in manual 4 1 Specifications Amperes In IE bu put At Rated ate ire Fee ire pen Load Output Welding re Speed Diameter Circuit Volt 50 60 4 pu pao Output g Range Range age Three Phase DC 400V Three 10 44 Standard 030 062 in 80 27 9 19 46 18 68 Phase 50 1400 0 8 1 6 mm 0 1 0 8 0 17 400 V ipm Input 450 A 36 5 V DC 1 3 35 6 mpm 10096 Duty Cycle While idling Input amperage fluctuates while idling and is always less than one Ampere Use one Ampere for power efficiency calculations feed speed
38. W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 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 220 389 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive 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 Ontario Canada LAW 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational A
39. age remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes after power is turned off before working on unit OR Check input capacitor voltage and be sure it is near 0 before touching any parts When power is applied failed parts can explode or cause other parts to explode Flying pieces of parts can cause injury Always wear a face shield when servicing unit Always wear long sleeves and button your collar when servicing unit After taking proper precautions as shown connect power to unit Warning Watch Out There are possible hazards as shown by the symbols Falling equipment can cause injury and damage to unit Always lift and support unit using both eye bolts Keep angle of lifting device less than 60 degrees Use a proper cart to move unit Do not use one eye bolt to lift or support unit S 179 309 5 3 2 Label Do not discard this product with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information OM 220 389 Page 12 3 3 Symbols And Definitions Amperage Direct Current Alternating Protective Earth G Three Phase Static Cj Frequency Con Increase i1 Line Connection Gea CMM TDA verter 9 Transformer Rectifier Primarv
40. 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 HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLE
41. cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal 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 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 Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 sparks and fire hazards OM 220 389 Page 2 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 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them
42. des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents telephone 1 877 413 5184 site Internet www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 telephone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 telephone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Considerations sur le soudage et le
43. ductor to supply grounding terminal first and never to a line terminal 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 10 Conductors must comply with national state and local electrical codes If OM 220 389 Page 20 applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief and tighten screws Use large strain relief for input conductor size 8 and larger Use small strain relief with reducing washers for input conductor size 10 Connect input conductors as shown in illustration Route green or green yellow grounding conductor through current transducer and connect to welding power source grounding terminal first Then connect input conductors L1 L2 and L3 to welding power source line terminals Reinstall side panel onto welding power Source Route input conductors C Route ground conductor through tubing and cur rent transducer to 803 855 A Ref 803 766 A 219 842 A Disconnect Device Power Connections Input 3 Disconnect Device switch shown in the OFF position 4 Green Or Green Yellow Grounding Conductor 5 Disconnect Device Grounding Terminal 6 Input Conductors L1 L2 And L3 7 Disconnect Device Line Terminals Connect green or
44. e l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer 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 Eneffectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des cables us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les p
45. en est quip D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante 5 Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme 29 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel d
46. erial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact 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 To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller 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 2007 Miller Electric Mfg Co 2007 01 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 2 Miller
47. faces of the weld cable terminal and copper bar are clean 4 9 Network Wire Feeder Receptacle Functions 7 Pin Pin Information REMOTE 9 A Not used B Shield C Volt sense D Can low E Can high F 24 volts dc common G 24 volts dc H Motor voltage 40 volts Motor voltage 40 volts Ref 803 417 A The remaining pins are not used 4 10 Electrical Service Guide A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source NOTICE INCORRECT INPUT POWER can damage this welding power source This welding power source requires a CONTINUOUS supply of input power at rated frequency 10 and voltage 10 Phase to ground voltage shall not exceed 10 of rated input voltage Do not use a genera tor with automatic idle device that idles engine when no load is sensed to supply input power to this welding power source Actual input voltage should not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available 50 60 Hz Three Phase Input Voltage 400 Input Amperes At Rated Output 28 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 Time Delay 2 35 Normal Operating 40
48. gs w Leads amp Current Xfmr including PTT 115092 THolisilig Pug SKIS s etg Eee T PDT 1150915 HOUSING PIU amp SKIS xa so rro te ERR MR eee ee TTC CT1 196231 Xfmr Current Sensing 200 1 eats eet 201695 Clamp Capacitor 226081 Capacitor Elctlt 2400 Uf 500 Vdc Can 2 50 Dia NL 210507 Clamp Capacitor Top Machined 217625 Kit Input Pre regulator And Inverter Module 24 RT1 RT2 214015 Thermistor NTC 30K Ohm 25 Deg C 7 amp 18in Lead 25 x POZ b 222661 Circuit Card Assy Power Interconnect OO sad 196143 Capacitor Polyp Met Film 16 Uf 400 VAC 10 po Ve M m 196378 Bracket Mtg Current Xfmr 29 dl soe 182918 Transducer Current 400A Module Supply V 15v 196384 6abl Transducer Ol au iu due Canc bbw inet by 29 ine IGE 196343 Resistors W Leads amp Plug 196840 Insulator Resistors Interface Board vs sce aes ba 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide ES cuta A
49. gue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES Ep SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n re
50. i ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e lsoler la pince de masse quand pas mis pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 220 389 Page 5 reste une TENSION DC NON dans les sources de soudage onduleur quand on a coup l alimentation e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre san
51. ice Agent M J Ny Every 3 x Unreadable Labels Weld Terminals x Damaged Gas Hose x Weld Cables Months X Cords X Gun Cables Every 6 Months Drive Rolls Inside Unit 7 2 Blowing Out Inside of Unit Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown Ref 803 410 B OM 220 389 Page 29 SECTION 8 SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury read and follow these precautions 8 1 Symbol Usage DANGER Indicates hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 8 2 Servicing Hazards 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 Only qualified persons should test maintain and repair this unit During servicing keep everybody especially children away 9 ELECTRIC SHOCK can kill e Do not touch live electrical parts e Turn Off welding power source
52. ificant DC voltage can remain on capacitors after unit is Off Always check the voltage on both Remove cover inverter assemblies as shown to be sure the input 1 Power Interconnect Board capacitors have discharged before working on unit PC2 2 Voltmeter Measure the dc voltage across the bus terminal and bus terminal on PC2 as shown until voltage drops to near 0 zero volts Measure input capacitor voltage on both inverter assemblies before proceeding 3 Typical Bleeder Resistor An example of a typical bleeder resistor is shown on this page Proceed with job inside unit Reinstall cover when finished lead to left bus terminal lead to right bus terminal Typical Bleeder Resistor 25 to 1000 ohm 5 watt resistor lead to left bus terminal lead to right bus terminal 5 16 AWG 1000 volts insulation rating approx 3 in 76 mm leads 802 985 Ref 803 419 B OM 220 389 Page 32 9 2 Process Control Module PC4 Diagnostic LED s 1 Process Control Module 4 D AT Diagnostic LED s are visible inside unit e located on PC4 mounted on the top tray Hefer to Section 9 3 for information on 1 diagnostic LED s Reinstall cover after checking diagnostic LED s oe ME ol OE Rus u alm ET LED2 D 0 mum mim Ta WO ange EU ort a om
53. ing power sources will not be correct at either sense lead and result in poor arc starts and arc quality OM 220 389 Page 25 B Better Setup Current Flow Path eee gt Ref 804 461 A 1 Welding Power Source 6 Wire Feeder the welding power sources The most 2 Electrode Cable accurate voltage sensing may not be une a eae ee This arrangement is a better setup for compensation in the welding parameters 5 Voltage Sensing Lead supporting separate voltage feedback to OM 220 389 Page 26 C Best Setup Current Flow Path eee gt Ref 804 462 A 1 Welding Power Source 5 Voltage Sensing Lead This arrangement is the best setup for 2 Electrode Cable proper voltage sensing at the workpiece 6 Wire Feeder Voltage feedback to the welding power 3 Feeder Cable sources will more accurate and result in 4 Work Cable 7 Workpiece reliable arc starts and better arc quality OM 220 389 Page 27 SECTION 6 OPERATION 6 1 Front Panel Switches Ref 803 418 B 1 Power Switch 2 Pilot Light 3 PDA Port Turns unit On or Off Light indicates status of welding power 4 Port source on when unit is on and off when unit is off OM 220 389 Page 28 SECTION 7 MAINTENANCE 7 1 Routine Maintenance A Disconnect power Maintain more often before maintaining during severe conditions y Check lt Change Clean x Replace Reference To be done by Factory Authorized Serv
54. ks 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 FLYING SPARKS can cause injury e Weara face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards le lt gt UN 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 53 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 e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIO
55. l LH w Components including 1 og PT 19635 T VVINGLUPING ET s s on aiit tta tod aie Mud tnt Re Rada e c eee aaa ore 1 ay eee ean INGUCION INOUN ead oi eve ttd 1 T te De 214519 Insulator Heat Sink Rectifier 1 T ses AG AGA 233092 RESIST GADOGIION auis este ence ena ate ars 1 5 UCET 199840 Bus Bar 2 OX wee Dui 201531 Kit Diode Power Module 2 cS 196347 Heat Sink Rectifier 2 23 eese yan 1 er ata tee 196349 Spacer Windtunnel 3 ass o Er 2094098 353 7 ATM nce a ed aae unte bs 1 1 d dede 220496 Output Inductor ASSY 1 AEE ns 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 2 179276 Bushing Snap in 1 000 Id X 1 375 Mig Hole Cent 4 196355 eae seca ed 6 010546 Bushing Snap in 375 Id X 500 Mtg Hole 1 222958 Windtunnel RH w Components including 1 ram 196332 s WNUN RAR 210 onto a cakes aa Ae eas e atn 1 030170 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole Cent 2 AJ 196259 Plu
56. lue 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 OVERUSE can cause OVERHEATING 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 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 install test and service H F producing units 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
57. nance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement specter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures EN e Porter un cran facial pour prot ger le visage el les yeux e Affuter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les
58. nd Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 48rd 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 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa 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 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator Do not coil or drape cables around your body 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 Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cuiting or induction heating operations If cleared by your doctor then following the above procedure
59. nect input power stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit INVERTER MJDULE 1 SECOMURY HEATSWK AEATSINK 4 a 3 LANA A INN TT TT add ttt ee eee amp res E RC4 7 gt INDUCTOR 7 a a CONTROL cr EXARD WT res REZ PLA RO3 PLGS RC4 PLG4 ROS PLES RGG PLGB JE RE7 PLE7 RG3 7 gt a Rcs PLE RcS 1 22 45 esi RO10 PLETO gt gt 8 17 AN 2 7E XRS 1 lt RCE 11 lt 966 10 CONTACTOR AT NOT READY 4G SUMMED SUMMED COM 2 AlLP CUMMANZ CON OC ed AC 1 2 PL lt RG2 amp RC3 4 sa m lt lt RO2 6 d a ul RC3 7 gt gt Aa 46 lt gt gt 24 7 AK RC2 9 RG3 Z RG2 2 1 gt lt RG2 3 a 3 nee Pez Rea BSL MMT Los RCZ PLCZ SES INTERCONNECT is are lt lt i BOARD ds RCI PLGI 1 RCG PLGE RCS PLG12 79 RC7 PLG7 RCS PLG1 lt RGI 3 RE FLGE waal RC10 PLG10 REI 1 gt lt RCS RCI 3 A RGI presa 961 727 lt res 7 RCI 2X 77 K pee 1 gt gt lt 5 8 Z lt lt 14 47 lt lt ROB 7 25 lt RES 13 47 RC6 1Z
60. nized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion m 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 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly
61. nt des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive
62. ntenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous 9 isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil
63. on of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except 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 Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns 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 normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured
64. onnected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill 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 If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present 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 Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power
65. propriate length for the application Whenever using long weld cables longer than 50 ft 15 m try to arrange positive and negative weld cables together to reduce the magnetic field surrounding the cables Avoid coupling the feeder and work sense leads with the weld cables Best Ref 804 458 A OM 220 389 Page 23 Welding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensity 5 4 Using Multiple Welding Power Sources Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder 7 Workpiece O1 amp Each welding power source should have a separate work cable connection to the workpiece Do not stack or join work cables together at the workpiece This is very important for pulse welding applications It is important to connect the voltage sensing lead as near to the weld as possible but not in the return current path Connect voltage sensing lead at the end of the weld joint The direction of the welding path should be away from the work cable connections Connect work clamp at the beginning of the weld joint Each welding gun should have its own source of shielding gas Use a separate shielding gas regulator and shielding gas connection for each welding gun Arc blow is the deflection of a welding arc from its normal path due to magnetic forces It will adversely affect the appearance
66. romagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 220 389 Page 8 Pour les moteurs essence Les gaz d chappement
67. s below for necessary actions to avoid the hazards FIRE OR EXPLOSION hazard e Do not place unit on over or near combustible surfaces e Do not service unit near flammables FLYING METAL or DIRT can injure eyes e Wear safety glasses with side shields or face shield during servicing e Be careful not to short metal tools parts or wires together during testing and servicing HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on equipment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns EXPLODING PARTS can cause injury e Failed parts can explode or cause other parts to explode when power is applied to inverters e Always wear a face shield and long sleeves when servicing inverters SHOCK HAZARD from testing e Turn Off welding power source and wire feeder or stop engine before making or changing me ter lead connections e Use at least one meter lead that has a self retaining spring clip such as an alligator clip e Read instructions for test equipment 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 f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit MOVING PARTS
68. s effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les cables de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes L4W 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other
69. s is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas Les dangers possibles sont montr s par les symboles peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc gt gt sh Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement mai
70. s m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 220 389 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br l
71. ship 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 delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w excepti
72. should be sized for Peak Amperage Apk for pulse welding applications 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 mm for metric use For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 S 0007 E C7 In pulse welding applications using inverter power sources peak currents can result in extreme voltage drops producing poor welding characteristics with undersized cables A recommendation for weld cable size is a minimum of 2 0 for 300 ampere welding power sources and 4 0 for 450 ampere welding power sources when total cable length is less than 100 ft 30m OM 220 389 Page 21 5 2 Welding Circuit Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics a Standard Welding Circuit Large Weld Structure OM 220 389 Page 22 Current Flow Path gt Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder 7 Workpiece O BR D In pulse welding applications using inverter power sources cable resistance can result in less than satisfactory performance In most cases a welding circuit length of 50 ft 15 m or less will provide satisfactory performance with a standard welding circuit connection The length of welding circuit is determined as follo
73. t e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais Seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations 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 for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous le
74. t There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arcrays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label 5 179 310 1 96 OM 220 389 Page 11 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Hazardous volt
75. tor light is lit when contactor line is asserted on Erratic or improper weld output with no errors displayed Use proper size and type of weld cable see Section 5 1 Clean and tighten all weld connections No 115 volts AC at the duplex receptacle Reset circuit breaker CB1 Wire does not feed Check circuit breaker CB2 and reset if necessary Check motor control cable connections Wire feeds erratically Readjust hub tension Readjust drive roll pressure Clean or replace dirty or worn drive rolls Remove weld spatter around the nozzle opening Replace contact tip or liner See gun Owner s Manual Check motor control cable connections Wire feeds as soon as power is supplied Check gun trigger See gun Owner s Manual Wire stubbing on low end using a Increase output setting of the power source constant current power source Check voltage sense lead connection clean and tighten if necessary Gas does not flow or does not stop flow ing wire feeds Check gas valve and flow meter Wire burns back to gun contact tip when using electrode negative straight polarity process Check to be sure that volt sense lead is connected to the work OM 220 389 Page 35 SECTION 10 ELECTRICAL DIAGRAMS 117 S AA o FERRITES TYP 3 PCS 55 o RC 1 PC4 PROCESS CONTROL BOARD J1 PLO33 J2 PLG34 J3 PLG3A J4 PLG82
76. tput is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes C7 Indicates special instructions zf This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards 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 c
77. ures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une lon
78. welding machine using shielded cables using line filters or shielding the work area OM 220 389 Page 3 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 Safety Code Section 25249 5 et seq 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 1 5 Principal Safety Standards Safety Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard
79. ws Welding Circuit Electrode Cable Length ECL Work Cable Length WCL Workpiece Length WL See Section 5 1 for weld cable size Variations in welding processes and welding circuit resistance can affect apparent voltage at the welding arc Voltage sensing can improve welding performance by providing accurate feedback to the welding power source It is important to connect the voltage sensing lead as near to the weld as possible but not in the return current path Ref 804 457 A 5 3 Arranging Welding Cables To Reduce Welding Circuit Inductance Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder Workpiece NO ND The method used to arrange cables has a significant affect welding properties As an example Accupulse and RMD welding processes can produce high welding circuit inductance depending on cable length and arrangement This can result in limited current rise during droplet transfer into the welding puddle The electrode sense lead is contained the feeder control cable and automatically becomes enabled for all semi automatic processes The work sense lead connects to the Axcess welding power source 4 pin connector located above the negative output terminal This work sense lead automatically compensates for work cable voltage drop when connected to Better the welding power source Do not coil excess cables Use cables that are the ap

Miller Electric Axcess 450 Welder User Manual

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