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Miller Electric 456P manual

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Table of contents for the manual

  • Page 1

    OM-185 648F July 2001 Processes Description MIG (GMA W) W elding With Optional Equipment: Pulsed MIG (GMAW -P) Arc Welding Power Source Invision 456P Visit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    dec_con1 10/95 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: Invision  456P conforms to the following Directives and Standards: Directives Electromagnetic compatibility Directive[...]

  • Page 5

    OM-185 648 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 safety message. . Means “ Note ” ; not safety related. This group of symbols means W arning! [...]

  • Page 6

    OM-185 648 Page 2 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. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and[...]

  • Page 7

    OM-185 648 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-185 648 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding 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 yea[...]

  • Page 9

    OM-185 648 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulie[...]

  • Page 10

    OM-185 648 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dan[...]

  • Page 11

    OM-185 648 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharg[...]

  • Page 12

    OM-185 648 Page 8 1-4. Principales normes de s é curit é Safety in W elding 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 Of fice, Washington, D.C. 20402. Recommended Safe Practice for [...]

  • Page 13

    OM-185 648 Page 9 SECTION 2 – DEFINITIONS 2-1. Manufacturer ’ s W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring 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 you[...]

  • Page 14

    OM-185 648 Page 10 > 60 s V S-179 190-A V V 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 5 Always wait [...]

  • Page 15

    OM-185 648 Page 1 1 2-2. Symbols And Definitions A Amperage Positive Remote V V oltage Output Circuit Breaker Negative On Of f Inductance Protective Earth (Ground) V oltage Input 2-3. Manufacturer ’ s Rating Label S-184 765[...]

  • Page 16

    OM-185 648 Page 12 SECTION 3 – INST ALLA TION 3-1. Specifications Input Power Rated W elding Output V oltage Range Maximum Open- Circuit Amperes Input At Rated Load Output 60 Hz, Three-Phase V oltage DC 400 V KV A KW Three Phase 450 A @ 38 V olts DC, 100% Duty Cycle; 565 A @ 38 V olts DC, 60% Duty Cycle 10 – 38 95 31 21.6 19.4 3-2. Duty Cycle A[...]

  • Page 17

    OM-185 648 Page 13 3-3. V olt-Ampere Curve va_curve1 4/95 – SA-181 562 V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown.[...]

  • Page 18

    OM-185 648 Page 14 14-1/2 in (368 mm) 3-4. Selecting A Location loc_2 3/96 - ST -800 61 1 / ST-801 718 1 Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit. 2 Lifting Handles Use handles to lift unit. 3 Hand Cart Use cart or similar device to move unit. 4 Rating Label Use rating label to determine input power ne[...]

  • Page 19

    OM-185 648 Page 15 3-5. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o 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 weld[...]

  • Page 20

    OM-185 648 Page 16 3-6. Remote 14 Receptacle Information Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB2. 24 VOL TS AC B Contact closure to A completes 24 volts ac con- tactor control circuit. AJ B K I 1 15 VOL TS AC I 1 15 volts ac. Protected by circuit breaker CB1. C L NH D M G 1 15 VOL TS AC J Contact clos[...]

  • Page 21

    OM-185 648 Page 17 3-7. 1 15 V olts AC Duplex Receptacle Ref. ST-801 524-A 1 1 15 V 7 A AC Receptacle Power is shared between duplex receptacle and Remote 14 recep- tacle (see Section 3-6). 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB 1 protects 1 15 volts ac portion of duplex receptacle and Remote 14 receptacle from overload. CB2 protects 24 vol[...]

  • Page 22

    OM-185 648 Page 18 3-9. Connecting Input Power ssb2.4* 1/94 – ST-801 718 / ST -801 946 T ools Needed: 5/16 in Input Fil t e r Board L1 =GND/PE Y Always connect grounding conductor first. Y T urn Off welding power source, and check voltage on input capacitors a c - cording to Section 5-3 before proceeding. Check input voltage available at site. Re[...]

  • Page 23

    OM-185 648 Page 19 SECTION 4 – OPERA TION 4-1. Front Panel Controls 1 Power On/Off Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 V oltmeter (see 4-3) 3 Ammeter (see 4-3) 4 V oltage Adjustment Control 5 Inductance Control Inductance determines the “ wetness ” of the weld puddle. When set higher ,[...]

  • Page 24

    OM-185 648 Page 20 4-3. Meter Functions The meters display the actual weld output values for approximately three seconds after the arc is broken. NOTE Mode Meter Reading At Idle Meter Reading While W elding MIG Preset V olts Blank VA 24.5 Actual V olts Actual Amps VA 24.5 250 Pulsed MIG Pulse Display Pulse Display VA PPP PPP Actual V olts Actual Am[...]

  • Page 25

    OM-185 648 Page 21 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Replace Cracked T orch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And T ighten W [...]

  • Page 26

    OM-185 648 Page 22 5-3. Removing Case and Measuring Input Capacitor V oltage Turn Of f welding power source, a n d disconnect input power . 1 Outside Handle Screws T o loosen top, remove two outside handle screws from both handles and all side bolts. 2 Interconnecting Board PC2 3 V oltmeter Measure the dc voltage across th e screw terminals on RC3 [...]

  • Page 27

    OM-185 648 Page 23 5-4. V oltmeter/Ammeter Help Displays . Al l directions are in reference to th e 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 mal[...]

  • Page 28

    OM-185 648 Page 24 5-5. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative. Place line disconnect switch in On position (see Section 3-9). Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 3-9). Check for proper input power connections (see Section 3-9). No weld output; meter display On[...]

  • Page 29

    OM-185 648 Page 25 Notes[...]

  • Page 30

    OM-185 648 Page 26 SECTION 6 – ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Welding Power Source[...]

  • Page 31

    OM-185 648 Page 27 SD-185 518[...]

  • Page 32

    OM-185 648 Page 28 SECTION 7 – P ARTS LIST . Hardware is common and not available unless listed. 801 930-C 1 2 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 43 4 44 45 46 48 49 50 46 51 52 53 57 58 36 60 59 61 62 63 64 4 PC1 PC2 3 65 4 5 6 7 8 30 10 47 54 55 56 66 Figure 7-1. Complete Assembly[...]

  • Page 33

    OM-185 648 Page 29 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly Quantity 1 187 234 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 195 585 HANDLE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 34

    OM-185 648 Page 30 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly (Continued) Quantity 53 HD1 168 829 TRANSDUCER, current 1000A max 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 S1 128 756 SWITCH, tgl 3PST 40A 600V AC scr 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 35

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y o ur distributor also gives you ... Service Y ou 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 [...]

  • Page 36

    PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F AX : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Headqua rters – United[...]