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Miller Electric 4500 Series manual

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Table of contents for the manual

  • Page 1

    Blu-Fab 3500 and 4500 Series Processes OM-221 677C 2006 − 07 Ef fective with serial number 222 842 Description MIG (GMAW) Welding Flux Cored (FCAW) Arc Welding Power Source OWNER’S MANUAL[...]

  • Page 2

    Thank you and congratulations on choosing Miller . Now you can get the job done and get it done right. W e 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 af [...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . [...]

  • Page 4

    dec_stat_Milan_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: ITW Welding Products Italy S.r .l. Mr . Danilo Fedolfi, Via Privata Iseo 6/E Managing Director 20098 San Giuliano ITW Welding Products Italy[...]

  • Page 5

    OM-221 677 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING eng_som_woPPS_3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special [...]

  • Page 6

    OM-221 677 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching[...]

  • Page 7

    OM-221 677 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-221 677 Page 4 1-4. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding Society Standard A [...]

  • Page 9

    OM-221 677 Page 5 SECTION 2 − DEFINITIONS W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock can kill. 1.1 W ear 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 Disconnec[...]

  • Page 10

    OM-221 677 Page 6 W arning! 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. Read the Owner ’ s Manual before working on this machine. 1 Consult rating label for input power requirements, and check power available at the job site − they [...]

  • Page 11

    OM-221 677 Page 7 SECTION 3 − INTRODUCTION 3-1. Included with Y our Unit 1 Power Source 2 Power Cord (4m) 3 Work Cable and Clamp (4m) 4 Running Gear 1 2 4 3 3-2. Specifications Rated Output at 45% Duty Cycle W elding Range Max. OVC Input Rating KV A Dimensions Net W eight Blu-Fab 3500 350 A 32 V 16-32 38 400 − 18A 1 1.8 KV A Length: 1040mm Heig[...]

  • Page 12

    OM-221 677 Page 8 SECTION 4 − INST ALLA TION 4-1. Selecting a Location Position unit so air can circulate. 500 mm 500 mm 500 mm 4-2. T ypical MIG Connections 1 Power source 2 W ork clamp (connect to receptacle as shown) 3 Cylinder (chain to running gear) 4 Cylinder valve Open valve slightly so gas flow blows dirt from valve. Close valve. 5 Regula[...]

  • Page 13

    OM-221 677 Page 9 4-3. Electrical Service Guide Blu-Fab 3500 Blu-Fab 4500 Input V oltage 400 400 Input amperes at rated output 21A 30A Fuse or circuit breaker rating (max. rec) 21A 30A Input conductor size 6 mm 2 6 mm 2 Grounding conductor size** 6 mm 2 6 mm 2 ** Larger power cord may be required for cable length greater than 3 meters. Consult nati[...]

  • Page 14

    OM-221 677 Page 10 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob, insert gun into block. Position outlet wire guide as close as possible to drive rolls without touching. T ighten knob. 4 Gun Trigger Plug 5 Gun Trigger Receptacle 6 Weld Cable T erminal 7 Weld Cable From W elding Power Source 4-6. Connecting W elding Gun And Wel[...]

  • Page 15

    OM-221 677 Page 1 1 SECTION 5 − OPERA TION 5-1. Controls 1 Power Switch The power switch is a selector knob which permits selection of operation on either of the two available ranges (I and II) and the center position is of f. 2 Indicator Lamp This lights up when the power switch is placed in the ON position. 3 Protection Fuse Fuse F protects the[...]

  • Page 16

    OM-221 677 Page 12 5-2. Panel Controls 1 2 3 4 5 7 8 9 10 6 1 V oltage Control 2 Purge Control 3 Jog 42 T − 4T Switch 5 Power ON-OFF 6 T orch Connection 7 Circuit Breaker 8 Gas In Connector 9 Control Cable Connection 10 Weld Cable Connection 5-3. Run-In Control and Burnback Control 2 4 6 8 10 2 4 6 8 10 t Run-In Control Use control to set wire fe[...]

  • Page 17

    OM-221 677 Page 13 SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Repair or replace cracked gas hose. Replace o-ring in Electrode/G[...]

  • Page 18

    OM-221 677 Page 14 Notes[...]

  • Page 19

    OM-221 677 Page 15 SECTION 7 - ELECTRICAL DIAGRAM RC1 RC2 RC1 IN RECT .TP OL R PL 22 20 21 1 15 BG A K I 14 13 20 1 15V 24V AT RC3 400V FM 9 10 230V S3 11 F GND R S T 5 3 1 W W W 2 S2 RL 1 SL 2 TL 3 6 4 7 19 8 RL 1 SL 2 TL 3 S3 PRI. B B B 2 1 2121 12 4 6 3 5 24 12 24 V ac DIGIT AL A-V 26 25 29 + SHUNT 1234 567 8 9 1 0 1 1 1 2 B B B MT SEC. SR1 Vc 2[...]

  • Page 20

    OM-221 677 Page 16 SECTION 8 - P ARTS LIST 8-1. Main Assembly 1 2 3 4 5 9 7 6 4 10 35 14 12 13 15 37 16 17 38 18 21 23 24 25 26 10 36 27 28 29 30 31 33 19 20 39 34 40 11 32 22 9/13/04 * * * 47 44 46 45 43 42 41 48[...]

  • Page 21

    OM-221 677 Page 17 Description Part No. Dia. Mkgs. Item No. 8-1. Main Assembly BF3500 BF4500 1 1 16121 1 19 Wrapper , T op cover 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 156002044 Handle Assy 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 22

    OM-221 677 Page 18 . Hardware is common and not available unless listed Figure 8-2. Wire Feed Assembly April 19, 2006[...]

  • Page 23

    OM-221 677 Page 19 Description Part No. Dia. Mkgs. Item No. Figure 8-2 . Wire Feed Assembly Qty 1 000058427 Ring 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 156032128 Spring 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 24

    OM-221 677 Page 20 . Hardware is common and not available unless listed Figure 8-3. Wire Drive Assembly (All Models) 1 2 3 4 5 7 6 8 9 10 11 12 13 14 15 16 17 18 19 20 4 9/13/04 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Wire Drive Assembly (All Models) Qty 1 057010052 Drive Motor , 24 VDC, 60w 1 . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 25

    Notes[...]

  • Page 26

    Notes[...]

  • Page 27

    Effective January 1, 2006 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED W ARRANTY − Subject to the terms and conditions below , ITW W elding Products Italy S.r.l., warrants to its original retail purchaser that new Miller equipment sold after t[...]

  • Page 28

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 1/06 I TW W elding Products Italy S.r . l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 email: miller@itw − welding.it Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address [...]