Miller Electric 456 CC Welder User Manual
Contents
1. 1 115V74A AC Receptacle Power is shared between duplex receptacle and Remote 14 recep tacle see Section 3 7 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects 115 volts ac portion of duplex receptacle and Remote 14 receptacle from overload CB2 protects 24 volts ac portion of Remote 14 receptacle from overload Press button to reset breaker Ref ST 801 524 A 3 9 Electrical Service Guide Input Voltage 400 Input Amperes At Rated Output 31 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 45 Min Input Conductor Size in AWG Kcmil 10 Max Recommended Input Conductor Length In Feet Meters 264 80 Min Grounding Conductor Size in AWG Kcmil 10 Reference 1993 National Electrical Code NEC S 0092J OM 188 422 Page 18 3 10 Connecting Input Power Per Input Filter Board S GND PE A Always connect grounding conductor first 1 Po a MS G Tools Needed B q CE 5 6 in ssb2 4 1 94 ST 801 523 B ST 801 946 A Turn Off welding power source and 1 Input And Grounding Conductors Select type and size of overcur2. 802 261 Figure 7 1 Complete Assembly 802 261 C OM 188 422 Page 30 No Mkgs No Description Quantity Figure 7 1 Complete Assembly e Ue UMORE seer ae 187 234 COVER jop 1 ed 195 585 s HANDLE EE 2 E M 190 373 PANEL side RH 2 1 Visa lt hare NACE EE 178 551 INSULATOR side 2 md veretur TE 185 836 LABEL warning electric shock 3 5 PC7 185 697 CIRCUIT CARD filter 2 1 Oran uM cre 185 210 BRACKET mtg filter board 1 AE Lass ipa e 189 440 TRANSFORMER HE 1 8 FM2 183 918 MOTOR fan 24VDC 3000RPM 43CFM w 10 ohm resistor 1 595 ouv PCT exo 184 141 CIRCUIT CARD ASSEMBLY control 1 AO LS e Cim oret is 194 371 SPACER al 3 5001g 1 ET 194 450 BRACKET mtg capacitor PC board fan 1 12 C3 6 192 935 CAPACITOR elctlt 2700uf 420 4 Tu eise res 181 925 INSULATOR stabilizer lead 1 14 ZA ER 180 029 STABIEIZER Output eihelietestebyere ene e de eM ee 1 15 5 Elise 180 026 INDUCTOR input 44 444 44e 1 16 12 3 sites 185 231 TRANSFORMER contro
3. 42222 12 SECTION 3 INSTALLATION ssseseee nnnm n nnn nn 13 Bat Specifications exte Usine tt oh AR Die E eB UOTE E 13 3 2 Duty Cycle And Overheating 13 3 3 VolEAmpere CUrVe coss oi e EDI E E Nee dE EE ELSE 14 3 4 Dimensions And Weight 14 3 5 Selecting A Location cog ei Ren Ter dE eet Tree deu Dette ER e ga 15 3 6 Weld Output Terminals And Selecting Cable Sizes 16 3 7 Remote 14 Receptacle Information 17 3 8 115 Volts AC Duplex Receptacle 18 3 9 Electrical Service Guide EES ESA REES AT Boa ete ANIME 18 3 10 Connecting Input Power 19 SECTION 4 OPERATION tI x si vee bese ine nee Suunto dela sieve ceeds 20 4 1 Front Panel Control8 ueneno rox edeemeie ri etie v che eme torre eee ed ede peste 20 4 2 Meter Functions 2229200 Uke g 2s EU ed 2a TAGS sde Oakes eee a oe ls 21 4 3 lt Mode Switch Settings ve dE et Eb ELE EC ILE EE RC tee nia RA 22 44 LiftAre TIG Procedure e Ne KN e RI ER e RERO EVE ewe beer been eed 23 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 24 5 1 Routine Maintenance ease TAKE aoe st ects oe Re eens tates toe atest RUBUS 24 5 2 Blowing Out In
4. 1 uv deutet RS 179 276 BUSHING snap in nyl 1 000 x 1 375mtg hole 1 Giorn cer ane der Een 185 214 BUS BAR interconnecting 1 EE 194 449 WINDTUNNEL RH 1 94 SR1 184 260 KIT diode power module 1 95 PM1 2 184 258 KIT transistor IGBT module 1 36 RT1 2 173 632 THERMISTOR NTC 30K ohm 25deg C 2 Macr AMD UE 179 930 HEAT SINK power module 1 EXC EP 204 165 HEAT SINK rect quad diode 1 raser d dre 190 272 BASE ue s chain ere ded ottawa ad eed at oed e Ci a 1 it AQ ess ser dud re 180 271 BRACKET mtg choke 1 MS p 182 654 GASKET DEL robert rom cree et ern eme 1 42 LIA 180108 crs COL DDT oi aurais sh anne tanins 2 PR EE 1 6 844 CORE f rril sas one eine en tele hale mines ke idea m scd RU 2 44 PC3 190 691 CIRCUIT CARD ASSEMBLY front panel 1 xA Dee deutet dan 182 707 TERMINAL power output black 1 46 C78 186 543 CAPACITOR ASSEMBLY 2 47 RGA 2 190 470 RECEPTACLE w leads capacitors plug 1 dA re de rate Y 180 732 BOOT n
5. 10 15 20 25 30 40 50 60 70 80 90 100 Continuous Welding A DUTY CYCLE 10096 Duty Cycle At 450 Amperes OD 60 Duty Cycle At 565 Amperes 5350 68 6 Minutes Welding 4 Minutes Resting Overheating Minutes LC OR AN Reduce Duty Cycle duty1 4 95 SA 181 560 OM 188 422 Page 13 3 3 Volt Ampere Curves Volt ampere curves show mini mum and maximum voltage and CV Modes amperage output capabilities of unit Curves of other settings fall be tween curves shown 100 80 ty 60 x D S 41 20 0 0 100 200 300 400 500 600 700 AMPERAGE CC Modes 100 VOLTAGE 100 200 300 400 500 600 700 AMPERAGE va_curve1 4 95 SA 181 561 SA 181 562 3 4 Dimensions And Weight Hole Layout Dimensions A 14 21 64 in 363 9 mm B 20 3 4 in 527 1 mm D SI C 23 27 64 in 594 9 mm mW D 24 31 32 in 634 2 mm db p C B E 12 3 8 in 314 3 mm F 9 32 in 7 1 mm Dia 15 1 2 in 394 mm Na Weight BEEN 118 lb 53 5 kg L E OM 188 422 Page 14 3 5 Selecting A Location E Movement Tipping A Do not move or operate unit where it could tip Location 1 Lifting Forks Use lifting forks to move unit Extend forks beyond opposite side of unit 2 Lifting Handles Use handles to
6. des TumEees toxiques cn eas eg soudage 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 OM 188 422 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc e Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds F LE SOUDAGE peut provoquer un TER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des
7. 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 Positive 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 Negative 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere S 0007 D OM 188 422 Page 16 3 7 Remote 14 Receptacle Information Ref ST 802 260 Lal REMOTE 14 Socket Socket Information A 24 volts ac Protected by circuit breaker CB2 24 VOLTS AC d OUTPUT B Contact closure to A completes 24 volts ac con CONTACTOR tactor control circuit 11 I SPI ircui k B1 115 VOLTS AC l 5 volts ac Protected by circuit breaker C OUTPUT J Contact closure to completes 115 volts ac con CONTACTOR tactor control circuit C Output to remote control 10 volts dc in MIG mode D Remote control circuit common REMOTE OUTPUT E 0 to 10 volts dc input command signal from re CONTROL mote control M Mode select N Remote inductance control A N F Current feedback 1 volt dc per 100 amperes AMPERAGE VOLTAGE H Voltage feedback 1 volt dc per 10 arc volts G Circuit common for 24 and 115 volts ac circuits GND K Chassis common The remaining sockets are not used OM 188 422 Page 17 3 8 115 Volts AC Duplex Receptacle ES e
8. 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 Arc rays 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 1 96 OM 188 422 Page 9 S 5 179 190 A Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 60 seconds 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 4 96 S 179 304 A Warning Watch Out There are possible hazards as shown by the symbols When pow
9. cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance Ki FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas oylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit b
10. lift unit 3 Hand Cart Use cart or similar device to move unit 4 Rating Label Use rating label to determine input INPUT SERIAL NO STOCK NO VOLTS AMPERES KW PHASE HERTZ power needs 5 Line Disconnect Device Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 loc 2 3 96 ST 800 611 ST 802 260 OM 188 422 Page 15 3 6 Weld Output Terminals And Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Total Cable Copper Length In Weld Circuit Not Exceeding T oncom ortess 7 3 23 7 1 7 609 1009 kee Mere PU GC Du 2 10 100 Duty Cycle Cycle Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2
11. proc d de soudage le demande les fum es e Sil utilisation d une source lectrique acourant lectrique s av re n ces e A l int rieur ventiler la zone et ou utiliser un chappement au niveau saire se servir de la fonction de t l commande si l appareil en est quip de l arc pour l vacuation des fum es et des gaz de soudage e Couper l alimentation ou arr ter le moteur avant de proc der l instal e Sila ventilation est insuffisante utiliser un respirateur alimenta lation la r paration ou l entretien de l appareil D verrouiller tion d air homologu l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de Se ET xe s curit e Lire les sp cifications de s curit des mat riaux MSDSs et les R instructions du fabricant concernant les m taux les consomma e Installer et mettre la terre correctement cet appareil conform ment bles les rev tements les nettoyants et les d graisseurs son manuel d utilisation et aux codes nationaux provinciaux et i n x municipaux e Travailler dans un espace ferm seulement S il est bien ventil ou en p i GER portant un respirateur alimentation d air Demander toujours un e Toujours v rifier la terre du cordon d alimentation V rifier et s assu surveillant d ment form de se tenir proximit Des fum es et des rer que le fil de terre du cordon d alimentation est bien raccord la gaz de soudage peuvent d placer l air et
12. 98290 1 Fax 39 02 98281 552 dec Con 10 95 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away IE ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulatin
13. ESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls In
14. MA 02269 O MOVING PARTS can cause injury e Keep away from moving parts such as fans CA e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference 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 f interference still occur
15. Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking or getting contaminated Do NOT Strike Like A Match Ref S 156 279 OM 188 422 Page 23 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance Maintain more often aH J Disconnect power us A s during severe conditions before maintaining i 3 Months WARNIN ME Replace Repair Or sm E Damaged Or Replace Replace Cracked Unreadable Cracked Torch Body Labels Cables Repair Or Replace Cracked Cables And Cords Clean And A Tighten vil 3 Weld Terminals e D iz 6 Months P d Blow Out Inside z 5 2 Blowing Out Inside Of Unit A Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown ST 802 260 OM 188 422 Page 24 5 3 Removing Case and Measuring Input Capacitor Voltage Turn Off welding power source and A Significant DC voltage can remain on capacitors af disconnect input power ter unit is Off Always check the vol
16. OM 188 422F June 2001 m T Multiprocess Welding The Power of Blue SS Description E3 Dz B4 Arc Welding Power Source Phoenix 456 CC CV us 400 Volt Models C EI OWNER S MANUAL Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service n RU E BI H E that meets the high standards of quality and value established in 1929 R This Owner s Manual is designed to help you get the most out of your Working as hard as you do every power source from Miller products Please take time to read the Safety precautions They Miller is backed by the most will help you protect yourself against potential hazards on the worksite hassle free warranty in the business We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintena
17. PLG3 RC5 PLG5 RC6 PLG6 RC7 PLG7 RC8 PLG8 RC9 PLG21 RC10 PLG22 RC4 PLG23 4 ILS Rc2 6 4 I lt lt Ro7 2 Figure 6 1 Circuit Diagram For Welding Power Source SHOCK HAZARD 9 Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit BLK BLK L1 LA AA A WHT ac s IEEE III o N ER t e6 O c1 c26 T o Ul SEN Qu Ml Ul I x Al E cn H 7 9 Il i3 ne de o e 9 o Il B A I orl e Hs Ill LA Ill o Ec Hl Sam o Be B PC5 GATE BD NM D RCI PLG16 c c D D LV M M M x EPA R Sf S RAA A 1 Y S RC6 1 gt gt I 8 8 8 g RC6 2 gt gt I RC3 455 2L i RC3 2 55 47 l 74 RC2 7 gt gt I RC2 1 gt gt _ 2 1 re2 8 gt gt 76 MEM RC2 4 gt gt RC9 325 HAT I RC9 125 244 PLG19 xa I x 1 HD1 x3 CD I a Lye 40 POSITIVE pu 42 rH LZE eO NEGATIVE TC 42 rH 192 795 OM 188 422 Page 29 SECTION 7 PARTS LIST LO N N Hardware is common and not available unless listed
18. Pulsed MIG CG GMAW P PPP PPP Pulse Display Pulse Display V A LS Remote 7 Control SMAW 85 Blank Preset Amps V A Panel Control p Pa 80 0 85 Actual Volts OCV Preset Amps OM 188 422 Page 21 4 3 Mode Switch Settings NOTE gt eliminates electrode sticking at arc start The SMAW modes provide the Adaptive Hot Start feature which automatically increases the output amperage at the start of a weld should the start require it This Mode Output Control or E Amp Lift Arc Trigger Select g LI Hold TIG GTAW Requires El gt Control TIG GTAW With Select CG LH HF Unit Pulsing Device Or Remote Control Requires gt Control Select E Volt CG MIG GMAW Requires Feeder Pulsed MIG A GMAW P Select Volt REPE an external pulsing device Requires A Feeder or Control Select s Amp L ey Remote 5 ZZZ control SMAW Requires 7 Control DI Panel Control Select or Li amp 7 SMAW Weld gt OM 188 422 Page 22 4 4 Lift Arc TIG Procedure With Mode switch in the Lift Arc TIG position start an arc as follows 1 TIG Electrode De 2 Workpiece Touch tungsten electrode to work piece at weld start point hold electrode to workpiece for 1 2 seconds and slowly lift electrode 1 2 An arc will form when electrode is Seconds lifted Touch
19. R PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL 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 WAR
20. RANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 7 00 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment sovice and Mapai Miller Electric Mfg Co Replace
21. abaisser le niveau d oxy borne de terre du sectionneur ou que la fiche du cordon est raccord e g ne provoquant des blessures ou des accidents mortels S assu une prise correctement mise la feng ie rer que l air de respiration ne pr sente aucun danger e En effectuant les raccordements d entr e fixer d abord le conducteur e Ne pas souder dans des endroits situ s proximit d op rations de de mise ala terre appropri et contre v rifier les connexions d graissage de nettoyage ou de pulv risation La chaleur et les e V rifier fr quemment le cordon d alimentation pour voir s il n est pas rayons de l arc peuvent r agir en pr sence de vapeurs et former des endommag ou d nud remplacer le cordon imm diatement s il est gaz hautement toxiques et irritants endommag un c ble d nud peut provoquer une lectrocution e Ne pas souder des m taux munis d un rev tement tels que l acier e Mettre l appareil hors tension quand on ne l utilise pas galvanis plaqu en plomb ou au cadmium moins que le rev te e Ne pas utiliser des c bles us s endommag s de grosseur insuffi ment n ait t enlev dans la zone de soudure que l endroit soit bien sante ou mal piss s ventil et si n cessaire en portant un respirateur alimentation e Ne pas enrouler les c bles autour du corps d air d aH tous GR m taux nin M l ments e Sila pi ce soud e doit tre mise la terre le faire directement avec un peuvenudegager
22. and related instructions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instr
23. avis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles 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 ex amin 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 Re search 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 con clusions finales de la recherche soient tab
24. ction Current O Percent Lift Arc Trigger 4 Pulsed gu V fA Hold Operation Single Phase 3 Three Phase GTAW l Rated Maximum Maximum Effective lricraaso H Lift Arc Operation 1max leff OM 188 422 Page 11 2 3 Manufacturer s Rating Label MODE C EN 60974 1 50A 10V 600A 38V xX 25 60 100 I2 450 L ee PETER A x 100 CODE EN 60974 1 EN 10V 550A 42V ez X 100 EON RN JD TE sagen Es BEE IP23 2xi 50 60Hz 110V 7A x100 S 184 765 S 184 763 OM 188 422 Page 12 SECTION 3 INSTALLATION 3 1 Specifications r Amperes Input Maximum At Rated Load Input Rated Welding Amperage Voltage Open Output 60 Hz Power Output Range Range Circuit Three Phase Voltage DC 400 V KVA KW 450 A 38 Volts DC Three 100 Duty Cycle Phase 565 A 38 Volts DC 5 600 10 38 95 31 21 6 19 4 60 Duty Cycle 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating ED If unit overheats thermostat s 500 i opens output stops and cooling 400 Beate fan runs Wait fifteen minutes for o unit to cool Reduce amperage or Ka 300 duty cycle before welding Exceeding duty cycle can lt damage unit and void war n 200 ranty E Li 150 100 0
25. duction Heating Power Sources Water Coolant Systems HFUnits Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue amp 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 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FO
26. e Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique 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 tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres LES FUM ES ET LES GAZ peuvent moyens isolants suffisamment grands pour emp cher le contact phy tre d sique ventuel avec la pi ce ou la terre etre dangereux e Ne pas se servir de source lectrique courant lectrique dans les zones Le soudage g n re des fum es et des gaz Leur humides dans les endroits confin s ou l o on risque de tomber inhalation peut tre dangereux pour votre sant e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le e Eloigner votre t te des fum es Ne pas respirer
27. e sure forks are long enough to extend beyond opposite side of unit Re LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards P 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 O N 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 5 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy
28. eg output stud 1 AO Lv scs Ee 179 848 BOOT pos output stud 1 E M 179 898 5 e PANEL TON i see euer xe Eques a e ae e Rata 1 I 181 245 TERMINAL power output red 1 52 xis SL 128 756 SWITCH tgl 3PST 40A 600VAC scr 1 Se aan tente da at Date que eR den 176 226 INSULATOR switch power d DS iad ruse Chet nr ee eimi e NAMEPLATE order by model and serial number 1 OM 188 422 Page 31 Item Dia Part No Mkgs No Description Quantity Figure 7 1 Complete Assembly Continued 54 HD1 168 829 TRANSDUCER current 1000A max 1 e rue 174 992 KNOB pointer 840dia x 250 ID 2 DOS Tran 174 991 KNOB pointer 1 250dia x 250 ID 1 MD TEM 179 851 KNOB pointer 1 670dia x 250 ID 1 DO Vas saca ed cedes 179 928 SHROUD fan 59 FM1 175 084 MOTOR fan 24VDC 3000RPM o EM C13 16 180 778 CAPACITOR ASSEMBLY 60 R12 C9 10 11 12 175 194 RESISTOR CAPACITOR 61 D1 4 201 531 KIT diode ultra fast recovery
29. er 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 4 96 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 handles Keep angle of lifting device less than 60 degrees Use a proper cart to move unit Do not use one handle to lift or support unit 1 96 OM 188 422 Page 10 2 2 Symbols And Definitions Alternating A Amperage Panel Current AC V Voltage e Output Circuit Breaker Remote On Gas Tungsten Arc Q Off Welding Negative Voltage Input BEEN Direct Current m Protective Earth l Positive Inductance DC Ground Constant Current Constant Voltage Foot Control E JD Line Connection Shielded Metal Arc Gas Metal Arc Three Phase Static Frequency Con Supply Current Supply Current GTAW AN Arc Force Welding SMAW Welding GMAW DEI voller Transformer Rectifier U Rated No Load U Primary Voltage Conventional X Duty Cycle 0 Voltage Average 1 y 9 Load Voltage y Yy Degree Of Rated Welding H Z Hertz I P Prote
30. et ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser 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 soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais 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
31. 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 Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance S Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour Soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppo
32. g gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 4 98 e A i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols
33. h For Air Carbon Arc CAC A cutting and gouging place switch in the Stick position For best results place Inductance Dig con trol in the maximum position 7 Inductance Dig Control Control adjusts Dig when the Stick or CC mode is selected on the Mode switch When set towards minimum short circuit amper age at low arc voltage is the same as normal welding amperage When set towards maximum short circuit amperageis increased at low arc voltage to assist with arc starts as well as reduce stick ing while welding see volt ampere curves in Section 3 3 Select setting best suited for application Control adjusts inductance when MIG posi tion is selected on the Mode switch Induc tance determines the wetness of the weld puddle When set towards maximum wet ness puadle fluidity increases When Pulsed MIG or one of the TIG modes is selected this control is not functional ST 184 762 A OM 188 422 Page 20 4 2 Meter Functions NOTE gt The meters display the actual weld output values for approximately three seconds after the arc is broken Mode Meter Reading At Idle V A 4 g La Lift Arc Trigger Uv Hold TIG GTAW 85 Blank Preset Amps V A fe Sf TIG GTAW 85 Blank Preset Amps V A G MIG GMAW 24 5 Preset Volts Blank V A
34. hooting pow Ss Trouble Remedy No weld output unit completely inop Place line disconnect switch in On position see Section 3 10 erative Check and replace line fuse s if necessary or reset circuit breaker see Section 3 10 Check for proper input power connections see Section 3 10 No weld output meter display On Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 3 2 Erratic or improper weld output Use proper size and type of weld cable see Section 3 6 Clean and tighten all weld connections No 115 volts ac output at duplex recep Reset circuit breaker CB1 see Section 3 8 tacle Remote 14 receptacle No 24 volts ac output at Remote 14 re Reset circuit breaker CB2 see Section 3 8 ceptacle OM 188 422 Page 27 SECTION 6 ELECTRICAL DIAGRAM A 34 GND n L2 0 L3 D deen J5 J Wi A PC7 232 W1 B RC9 102 5 1 ar WI RC2 115V RCPT e HOT gt gt NEUTRAL GND 42 CB1 400V 10 lt lt RC7 14 E RC7 12 RC7 10 Ca RC7 8 l RC9 8 gt gt RC9 6 22 vvv 3 LAN FED gt s PLG10 RC10 Re s1svac gt sr CB2 18 18V 18V GRA Zu D
35. istant mate rial leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding
36. l 200 400VAC 1 d nor ss Me AD muscis 180 105 BRACKET mtg transformer aux 1 18 CB2 093 995 CIRCUIT BREAKER man reset 15A 1 19 CB1 161 078 CIRCUIT BREAKER man reset 7A 1 seus RO2 s 604 176 RECEPTACLE str dx grd 3W 15A 120V 1 Ap PLATE identification order by model amp serial number 1 M 175 282 COVER receptacle weatherproof 1 eas ru eterne 11872933 E EE 1 foto t deut eta 185 526 LABEL warning electric shock HR Se de a does Sl 23 Dol exe ERSRI 153 403 BUSHING snap in nyl 750 ID x 1 000mtg hole 2 ed sci erdt es 025 248 STAND OFF insul 250 20 x 1 2p0lo nnn 4 mui p W1 180 270 CONTACTOR def prp 40A 3P 24VAC 1 o6 iu O2 uw 186 015 CAPACITOR polyp film 34uf 1000VAC 2 vac vasi dut TERTII Dd 185 992 BUS BAR capacitor 2 28 CT1 181 271 TRANSFORMER current 500 turns 1 mue oos oe 177 547 BUSHING snap in nyl CT MT 1 125mtg hole 1 90 T4 185 208 CHOKE common mode 1 31 PC2 187 243 CIRCUIT CARD ASSEMBLY interconnect
37. lies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 188 422 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos 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 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Manufacturer s Warning Label Definitions Warning Watch Out 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
38. ls en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas 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 re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES T peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 188 422 Page 6 LES ACCUMULATIONS DE GAZ ris quent 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 confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistol
39. lt o lt 24VAC gt gt 24V RMT B DCONTACTOR Le X Rc2 8 RMT OUT REF COM D an eS RC2 7 m 1V 100A F gt X X RC2 4 1V 10V 19 0X un SE EE RC2 3 Lu It 30 SPEEN UU ec RC2 10 C11 M IT 24 C135 D 29 T H gt X RC2 9 115V RMT C15 D 25 rn D RC2 5 CONTACTOR MODE z GND 4 O C9 ER 43 D or SK R22 C16 ei 44 RMT B gt NDUCTANCE t Ke Reese C17 42 ER lt RC2 2 PC3 FUNCTION METER BI RC2 PLG1 1 RC4 PLG17 RC5 PLG18 RC1 RC4 1 gt RC4 2 gt l RC5 1 gt RC5 2 gt OM 188 422 Page 28 RT2 RT 1 EU X RCB 2 RED lt RCB 1 BLK lt RC10 2 RED lt RC10 1 lt lt RC2 4 AK RC3 12 gt gt lt lt RC2 1 L WHT RC3 10 gt gt RC3 6 gt gt lt lt RC2 6 ALK RC3 8 gt gt PC2 INTERCONNECT BD RC7 400V RC2 PLG12 RC9 PLG9 o Io 95 1 lt lt RC2 3 C1 A N nt C2 E1 PM1 B1 G1 vi N DO 2 E1 N hl LA 71e 5 2 WAT RC5 2 gt BLK lt RC1 1 RC5 7 gt WHT PC4 GATE BD RC1 PLG15 RC1 3 RC1 4 lt RC1 2 BLK WHT M tl II tl M RC5 5 gt RC5 10 gt PC1 CONTROL BD RC1 PLG1 RC2 PLG2 RC3
40. ment Parts An Illinois Tool Works Company 1635 West Spencer Street Training Schools Videos Books Appleton WI 54914 USA ae International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department Miller The Power of Blue PRINTED IN USA O 2001 Miller Electric Mfg Co 1 01
41. nce And if for some reason the unit needs repair REGISTERED QUALITY SYSTEM there s a Troubleshooting section that will Miller is the first welding help you figure out what the problem is The equipment manufacturer in ins LS A to be registered fo parts list will then help you to decide which the ISO 9001 Quality System exact part you may need to fix the problem Au Warranty and service information for your particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Miller The Power of Blue amp WARNING This product when used for welding or cutting 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 The following terms are used intercha
42. ngeably throughout this manual TIG GTAW Stick SMAW OM 188 422 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage is crea sb ERNEIEREN d fad tir x gu Aa 1 1 2 Arc Welding Hazards ss cene ree PYAR ek a ee RR Ren Era et 1 1 8 Additional Symbols For Installation Operation And Maintenance 3 1 4 Principal Safety Standards 3 1 5 EME Informatior 23 ege hat r A nr a A thue ev Iti Un er let 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 1 1 Signification des symboles 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement otla maintenance site mienne res ket Fed vie Ces anf Ce I E E OE Et 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 DEFINITIONS 44444 ses 9 2 1 Manufacturers Warning Label Definitions 9 2 2 Symbols And Definitions 11 2 3 Manufacturers Rating Label
43. npn 179 826 INSULATOR rectifier RENE 179 902 WINDTUNNEL UH B4 a ou b WE ges 183 827 sse BUS BAR output s bellu dg te rire et e nen TERRE 179 276 BUSHING snap in nyl 1 000 x 1 375mtg hole Oasis ah entes 179 310 LABEL warning general precautionary 2 EE PLG4 131 056 HOUSING RECEPTACLE amp SOCKETS 1 Gp POR RC10 166 679 HOUSING RECEPTACLE PINS amp SOCKETS 1 nest PLG2 115 092 HOUSING PLUG amp SOCKETS 1 hee PLG7 19 115094 HOUSING PLUG amp SOCKETS 1 TE ANE PLG9 11 115091 HOUSING PLUG amp SOCKETS 1 E PLG3 12 180 776 PLUG w leads voltage feedback 1 EAE PLG5 15 16 175026 PLUG w leads 1 NM PLG21 181 410 PLUG w leads 1 MAO os eii 190 271 PANEL side LH apis feted nian SLE ce eh Rea 1 E th Eee ieee eed 199 840 BUS BAR diode 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 Part
44. ntil 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 188 422 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION AEN Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger som nd fre 4 98 1 1 A identifie un message de s curit particulier Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l a
45. oit pos et mis la terre conform ment ce mode d emploi e Encasd iterf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 188 422 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson D
46. pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit 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 pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventue
47. r mal protection circuitry located on the left side of the unit If this display is shown contact a Factory Autho rized Service Agent 3 Help 3 Display Indicates the left side of the unit has overheated The unit has shut down to allow the fan to cool it see Sec tion 3 2 Operation will continue when the unit has cooled 4 Help 4 Display Indicates a malfunction in the ther mal protection circuitry located on the right side of the unit If this dis play is shown contact a Factory Authorized Service Agent 5 Help 5 Display Indicates the right side of the unit has overheated The unit has shut down to allow the fan to cool it see Section 3 2 Operation will contin ue when the unit has cooled 6 Help 6 Display Indicates that the input voltage is too low and the unit has automati cally shut down Operation will con tinue when the voltage is within 15 of the operating range If this display is shown have an electri cian check the input voltage 7 Help 7 Display Indicates that the input voltage is too high and the unit has automati cally shut down Operation will con tinue when the voltage is within 15 of the operating range If this display is shown have an electri cian check the input voltage 8 Help 8 Display Indicates a malfunction in the sec ondary power circuit of the unit If this display is shown contact a Factory Authorized Service Agent OM 188 422 Page 26 5 5 Troubles
48. rc A Les symboles pr sent s ci apr s sont utilis s tout au long du e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le pr sent manuel pour attirer votre attention et identifier les risques champ les pi ces endommag es Entretenir l appareil conform ment de danger Lorsque vous voyez un symbole soyez vigilant et ce manuel suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer e Porter un harnais de s curit quand on travaille en hauteur l information contenue dans les normes de s curit num r es 1 la section 1 4 Veuillez lire et respecter toutes ces normes de Maintenir solidement en place tous les panneaux et capots s curit e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal EE L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous avec la pi ce souder ou la table de travail le plus pr s possible de la soudur
49. rent protec check voltage on input capacitors ac See Section 3 9 tion using Section 3 9 Connect input and ns to Section 5 3 before Install ring terminals of proper size onto input grounding conductors to a deenergized line pacer d conductors for connection to input filter disconnect device Check input voltage available at site board terminals see illustration Remove left side panel 2 Line Disconnect Device Reinstall left side panel OM 188 422 Page 19 SECTION A OPERATION 4 1 Front Panel Controls 1 Power Switch The fan motor is thermostatically controlled and only runs when cooling is needed Voltmeter see Section 4 2 Ammeter see Section 4 2 V A Voltage Amperage Adjust Control Voltage Amperage Control Switch For front panel control place switch in Panel position and use the V A Adjust control af I For remote control make connections to Re mote 14 receptacle and place switch in Re mote position In most modes remote control is a percent of the V A Adjust control setting Value selected on V A Adjust is maximum available on remote In the MIG mode re mote control provides full range of unit output regardless of V A Adjust control setting 6 Mode Switch The Mode switch setting determines both the process and output On Off control see Sec tion 4 3 Source of control panel or remote for the amount of output is selected on the V A Control switc
50. s de l appareil nn jt i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT a e Pr voir une p riode de refroidissement respec v ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s 79 amp 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 antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande 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 person nes ou toute pi ce m canique en engageant le fil de soudage 5 d DES ORGANES MOBILES peuvent provoquer des blessures CA e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute frequence peut provoquer des in
51. s Model and serial number required when ordering parts from your local distributor OM 188 422 Page 32 Notes OM 188 422 Page 33 Notes OM 188 422 Page 34 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPR
52. s the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 188 422 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the 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 U
53. side Of Unit 24 5 3 Removing Case And Measuring Input Capacitor Voltage 25 5 3 Voltmeter Ammeter Help Displays 44442 26 5 4 Troubleshooting lt s cre 4422444 NEEN e RR tebe eR AR RE ag bee LESE RR EA PE 27 SECTION 6 ELECTRICAL DIAGRAM n nnn 28 SECTION 7 PARTS LIST 2 tee masse nee eee anis dees a rs 30 WARRANTY Declaration of Conformity For European Community CE Products Manufacturer s Name Miller Electric Mfg Co Manufacturer s Address 1635 W Spencer Street Appleton WI 54914 USA Declares that the product P h oe n i X B 45 6 C C C V conforms to the following Directives and Standards Directives Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 December 1995 Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1989 Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 664 1 1992 European Contact Mr Danilo Fedolfi Managing Director MILLER Europe S r l Via Privata Iseo 20098 San Giuliano Milanese Italy Telephone 39 02
54. tage as shown to be sure the input capacitors have discharged be 1 Outside Handle Screws Ibteiwonng onunit To loosen top remove two outside 1 handle screws from both handles and all side bolts 2 Interconnecting Board PC2 3 Voltmeter Measure the dc voltage across the screw terminals on RC3 and RC5 as shown until voltage drops to near 0 zero volts Proceed with job inside unit Rein stall cover when finished lead to lower right terminal lead to SC upper right terminal olofo Tools Needed C Lu sh in ST 802 260 ST 801 536 OM 188 422 Page 25 5 4 Voltmeter Ammeter Help Displays I IT m Di V A HE Cu P 2 V A L Ti ES P CO lt SS y E lt T H Ee lt lt I H Ss lt Ss u L A U Uj U gt N OJ EF All directions are in reference to the front of the unit All circuitry referred to is located inside the unit 1 Help 1 Display Indicates a malfunction in the pri mary power circuit If this display is shown contact a Factory Autho rized Service Agent 2 Help 2 Display Indicates a malfunction in the the
55. terf rences avec les quipements de ra dio navigation et de communication 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 L utilisateur 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 appa reil 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 distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique 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 com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles 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 quipement lectronique sensible e Veiller ce que ce poste de soudage s
56. uctions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 188 422 Page 1 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 e Weara welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame res
57. wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Eq FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 188 422 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani
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