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Miller Electric 400 manual

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  • Page 1

    p Visit ou~ webs~te at Www~MllI~rWeIds.com Miller The Power OJIB& OM-iBO 424E August 1998 Processes ~ MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 400 OWNERS MANUAL[...]

  • Page 2

    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 c[...]

  • Page 3

    TABLE OF CONTENTS The following term is SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING 1 used interchangeably throughout this manual: 1-1. Symbol Usage 1 MIG=GMAW 1-2. Arc Welding Hazards 1 1-3. Additional Symbols For Installation, Operation, And Maintenance 3 1-4. Principal Safety Standards 3 1-5. EMF Information 4 SECTION 1 - CONSIGNES DE SEC[...]

  • Page 4

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  • Page 5

    SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1 1 Synibol Usage 4A Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. A Marks a special safety message. ff7 Means Note~ not safety related. 1-2 Arc Welding Hazards A The symbols shown below are u[...]

  • Page 6

    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 a welding helmetfitted with a proper shade of filterto protect your face and eyes when welding or watching (see ANSI Z49.i and Z87.i listed in Sa[...]

  • Page 7

    FIRE OR EXPLOSION hazard.  Do not install or place unit on, over, or near combustible surfaces.  Do not install unit near flammables.  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.  Use lifting eye to lift unit only, NOT running g[...]

  • Page 8

    1-5.. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator. magnetic fields. There has been and still is som[...]

  • Page 9

    SECTION 1 - CONSIGNES DE SECURITE - LIRE AVANT UTILISATION som _nd_fre 5/97 1-1 Signification des symboles a Signifie Mise en garde! Soyez vigilant! Cette procedure prØsente des risques de danger! Ceux-ci sont identifies par des symboles adjacents aux directives. A Identifie un message de sØcuritØ particulier. ~ Signifie NOTA nest pas re/at/f[...]

  • Page 10

    LES RAVONS DE LARC peuvent pro voquer des brlures dans les yeux et sur Ia peau. Le rayonnement de larc du procØdØ de soudage genere des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des bthlures dans es yeux et sur Ia peau. Des Øtincelles sont projetØes pendant le soudage.  Porter un [...]

  • Page 11

    1 -3. Dangers supplØmentaires en relation avec linstallation, le fonctionnØrnent et Ia maintenance Risque DJNCENDIE OU DEXPLOSION.  Ne pas placer lappareil sur, au-dessus ou a proximitØ de surfaces infilammables.  Ne pas installer lappareil a proximite de produits inflammables  NepassurchargerlinstallationØlectrique - s?[...]

  • Page 12

    1-4. Principales normes de sØcuritØ Safety in Welding and Cutting, norme ANSI Z49. 1, de IAmerican Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet ding Society, 550 NW. Lejeune Rd, Miami FL 33126 P-i, dela Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA 22202. Safetyand Health Sandards, OSH[...]

  • Page 13

    2-1. Specifications SECTION 2 - INSTALLATION 400 g~ 500 ~0 z zxj 150 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 voltage, or duty cycle before welding. A Exceeding dut[...]

  • Page 14

    2-3. Volt-Ampere Curve 1 Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output ca pabilities of the welding power source. Curves of other settings fall between the curves shown. 2 Overload Volt-Ampere Curves When unit is used beyond capac I ity, circuitry senses the overload iI and sh[...]

  • Page 15

    2-5. Installing Welding Gun (Gun Not Included) 2-6. Setting Gun Polarity For Wire Type 4 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun end through opening until it bot toms against drive assembly. Tighten knob. 4 Gun Trigger Plug 3 Insert plug into receptacle, and tighten threaded collar. Close door. Ret. ST-801 77[...]

  • Page 16

    2-7. Remote 14 Receptacle Argon Gas ORQ Typical flow rate is .57 cmh (cubic meters per hour). Check wire man ufacturers recommended flow rate. 4 CO2 Adapter 5 0-Ring i~:i REMOTE 14 Socket* Socket Information A f~ OWPUT ~ (cONTACTOR) 24 volts ac. Protected by circuit breaker CB2. B 010 Contact closure to A completes 24 volts ac contactor control [...]

  • Page 17

    2-9. Installing Wire Spool and Adjusting Hub Tension OM-189 424 Page 13[...]

  • Page 18

    2-10. Inductance Selection H Weld Bead Using The Tap Stabilizer Connection With 17 Volts, 100 Amps II Weld Bead Using The End Stabilizer Connection With 17 Volts, 100 Amps Remove left side panel. 1 Stabilizer Z Tapped stabilizer Z is factory con nected to the stabilizer tap which suits most GMAW applications. Stabilizer Z controls the induc tance a[...]

  • Page 19

    2-12. Selecting a Location and Connecting Input Power Have only qualified persons make this installation. 1 Rating Label Check input voltage available at site. Remove wrapper. 2 Jumper Link Label Tools Needed: ===z ~ 3/8 in c:I::::::1:=:=~lJ 3/8 in GND/PE GND/PE Connect First Size and ratings must comply with applicable codes (see Section 2-11). In[...]

  • Page 20

    2-13. Threadrng Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. Tools Needed: Close and tighten pressure assembly, and let go of wire. -* Remove gun nozzle and contact tip. Turn On. Press gun trigger until wire comes out of gun. R[...]

  • Page 21

    3-1. Controls SECTION 3 OPERATION OM-189 424 Page 17[...]

  • Page 22

    SECTION 4- MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance ~ I A : Disconnect power before maintaining, Maintain more often during severe conditions. 4-3. Unit Overload If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun trigger to reset this condition. 4-2. Circuit Bre[...]

  • Page 23

    4-4. Changing Drive Roll and Wire Inlet Guide NOTE: Drive rolls and inlet wire guide are not included. See Table 6-1 for ordering informa tion. 1 Securing Screw 2 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Anti-Wear Guide Install guide as shown. 4 Drive Roll Install correct drive [...]

  • Page 24

    4-6. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-12). Replace building line fuse or reset circuit breaker if open (see Section 2-12). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections (see Section 2-5, and see gun Owners Manual). Have Factory Aut[...]

  • Page 25

    SECTION 5- ELECTRICAL DIAGRAM Figure 5-1. Circuit Diagram SD-I 89 410 OM-189 424 Page 21[...]

  • Page 26

    SECTION 6- PARTS LIST Figure 6-1. Main Assembly ST-802 104 a, Hardware is common and not available unless listed. 0 a, cJ (0 U- / / / / cJ (I (0 LL U) c~) (0 ci, U- (0 OM-1 89424 Page 22[...]

  • Page 27

    Item Dia. Part No. Mkgs. No HOUSING RECEPTACLE & SOCKETS 1 BAFFLE, center w/components 1 TRANSFORMER, pwr main 1 THERMOSTAT, NO 1 PANEL, rear w/components 1 PANEL, side LH 1 LATCH, slide flush mtg hole 1.000 wide x 1.500 Ig 2 PANEL, side 1 LABEL, warning general precautionary 1 WRAPPER 1 CABLE, pwr 1 2ft 8ga 4/c 1 ...BASE 1 ...WHEEL 2 AXLE, run[...]

  • Page 28

    Hardware is common and not available unless listed. U- Figure 6-2. Baffle, Center w/Components ST-8O1 952-A / / 0 0) Co CO C~) cJ (0 C 0) 0 C Cj  C CJ U Co OM-1 89 424 Page 24[...]

  • Page 29

    Item Dia. Part No. Mkgs. No. RING, retaining spool 1 NUT, stl hex full .625-11 1 WASHER, flat stl .640 ID x 1.000 OD x 1 4ga thk 1 SPRING, cprsn .845ODx.ll0wirexl.500 1 WASHER, flat stl keyed 1.500diax .l25thk 1 SPRING, cprsn 2.430 OD x .090 wire x 2.500 1 HUB, spool 1 WASHER, brake 1 REEL, support 1 BAFFLE, center, (consisting of) 1 COVER, primary[...]

  • Page 30

    Figure 6-3. Panel, Front w/Components (Fig 6-1 Item 16) 1 +188 711 .. PANEL, front control 1 189 350 .. LABEL, nameplate 1 2 . . .. R2,3 035897.. POTENTIOMETER 2 3 .... Cl 185 890 .. LEAD ASSEMBLY, elect 1 4 .... C2 185896.. LEAD ASSEMBLY, elect 1 5 .. C13-15 148 240 .. CAPACITOR, cer disc .OO3uf 2000VAC 3 6 186473.. PANEL,front 1 7 .... 51 128 756[...]

  • Page 31

    Item Dia. Part No. Mkgs. No. Description Quantity Figure 6-4. Wire Drive And Gears (Fig 6-2 Item 27) 1 602 009 ... SCREW, .250-20 x 1.25 soc hd gr 8 1 2 172 075 ... CARRIER, drive roll w/components 1 3 166072 ... SPACER, gear 1 4 010224...PIN,springCS.187x1.000 1 5 182 788 ... HOUSING, adapter gun/feeder 1 6 085 242 ... FASTENER, pinned 1 7 085 244[...]

  • Page 32

    Item Dia. Part No. Mkgs. No. Table 6-1. Drive Roll And Wire Guide Kits Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V-Knurled rolls for hard shelled cor[...]

  • Page 33

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  • Page 35

    LIMITED WARRANTY - Subject to the terms and conditions below, Miller Electric Mtg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date otthis limited warranty is free of defects in material end workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU [...]

  • Page 36

    Miller Electnc Mtg Co M Illtnois Tool Works CÆmpaæy 1635 West Spencer Street Appleton WI 54914 USA International Headquarters-USA Phone; 920~35~4505 : USA &Canada FAX: 920L73&4134 lntemattonal F~4X 920 735-4125 European Headquarters - UnitedKingdom Phone: 44 (0)1204593493 FAX: 44 (0) 1204598966 www MillerWelds corn The Thwer jlikw Owner?[...]