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Miller Electric 460Volt manual

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Table of contents for the manual

  • Page 1

    File: MIG (GMA W) Invision 354MP (230/460 And 460/575 V olt Models) Processes OM-188 304AF 2007 − 10 Processes Description Stick (SMAW) W elding MIG (GMAW) Welding Pulsed MIG (GMAW -P) Arc Welding Power Source With Built-In Synergic Control R 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 specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • 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

    [...]

  • Page 5

    OM-188 304 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols[...]

  • Page 6

    OM-188 304 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Page 7

    OM-188 304 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-188 304 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and [...]

  • Page 9

    OM-188 304 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures gra[...]

  • Page 10

    OM-188 304 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

  • Page 11

    OM-188 304 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 12

    OM-188 304 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher d[...]

  • Page 13

    OM-188 304 Page 9 2-5. P ri nc ipa le s no rm e s de s écu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American[...]

  • Page 14

    OM-188 304 Page 10[...]

  • Page 15

    OM-188 304 Page 1 1 SECTION 3 − INTRODUCTION 3-1. Specifications Rated Output at V oltage Range in Amperage Range in Max. Open- Circuit RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Load V oltages and Class I Rating Rated Output at 60% Duty Cycle Range in CV Mode Range in CC Mode Circuit V oltage 230 V 460 V KV A** KW** 300 A at 32 V[...]

  • Page 16

    OM-188 304 Page 12 3-3. V olt-Ampere Curves va_curve1 4/95 − SA-188 537 / SA-178 653 V olt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. CC Mode CV Mode[...]

  • Page 17

    OM-188 304 Page 13 SECTION 4 − INSTALLATION 4-1. Selecting A Location loc_2 3/96 - Ref. ST -151 556 / ST-802 167 1 Lifting Handles Use handles to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Locate unit near correct input power supply . ! S[...]

  • Page 18

    OM-188 304 Page 14 4-2. W eld Output Receptacles And Selecting Cable Sizes ! 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 19

    OM-188 304 Page 15 4-3. Remote 14 Receptacle Information Socket* Socket Information AJ 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB2. AJ B K I C L NH 24 VOL TS AC B Contact closure to A completes 24 volts ac contactor control circuit. C L NH D M G F 1 15 VOL TS AC I 1 15 volts ac. Protected by circuit breaker CB1. E F 1 15 VOL TS AC [...]

  • Page 20

    OM-188 304 Page 16 4-5. Electrical Service Guide NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency (+ 10%) and voltage (+ 10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera- tor with automatic id[...]

  • Page 21

    OM-188 304 Page 17 4-6. Connecting 1-Phase Input Power 2/04 - Ref. 802 136-A / 801 192 ! Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tag- out input power before con- necting input conductors from unit. ! Always connect green or green/yellow conductor to suppl[...]

  • Page 22

    OM-188 304 Page 18 4-7. Connecting 3-Phase Input Power 2/04 - Ref. 802 136-A / 801 192 ! Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. ! Disconnect and lockout/tagout in- put power before connecting input conductors from unit. ! Always connect green or green/ yellow conductor to suppl[...]

  • Page 23

    OM-188 304 Page 19 SECTION 5 − OPERATION 5-1. Front Panel Controls 1 Power Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 V oltmeter (see Section 5-2) 3 Ammeter/T ri m Indicator (see Section 5-2 ) 4 Ammeter Light Lights when display beneath is indicating amperage. 5 Trim Indicator Light Lights when d[...]

  • Page 24

    OM-188 304 Page 20 5-2. Meter Functions . The meters display the actual weld output values for approximately three seconds after the arc is broken. 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 Blank Pulse Display V T rim 50 Actual V olts Actual Amps VA 24.5 [...]

  • Page 25

    OM-188 304 Page 21 5-3. Example Displays Amperage preset display for Stick welding mode. V oltage preset display for MIG welding mode. Display while welding. Preset trim display for Pulse welding mode. Preset pulses per second (PPS) display for Manual Pulse welding mode. . Values shown are hypothetical. The “A” (Amperage) and “T rim” lights[...]

  • Page 26

    OM-188 304 Page 22 T u rn Output Adjust control to set arc length to 36. > P r g 7 035 A l 5356 A r A dap t i v e P u l s e 5-4. Synergic Controls And Overview Controls 1 Display 2 Parameter Select Push Button Press button to move > on display . The parameter indicated by > is selected. 3 Increment Push Button Press increment button to inc[...]

  • Page 27

    OM-188 304 Page 23 5-5. Initial Display , Manual Pulse MIG Mode, MIG Mode, And Stick Mode 1 Software Program Number When power is applied, initial dis- play with software number appears momentarily , and then last program to be viewed before control was shut down appears. 2 Manual Pulse MIG Mode The synergic control functions as a discrete pulsed M[...]

  • Page 28

    OM-188 304 Page 24 5-6. Setup Screens T o access Setup screens: turn welding power source Of f, press and hold Select push button, turn unit On, and hold push button down until initial screen leaves. T o exit Setup screens, turn welding power source Off and then On again. Parameters that are dis- played when the Setup screens are exited are active.[...]

  • Page 29

    OM-188 304 Page 25 5-7. Choosing Pulse Programs And Setting Parameters > P r g 2 045 S t A r / C O 2 Ad a p t i v e Pu l s e Setting Arc Length: Arc length is adjusted with the Output Adjust control. Dis- played preset Trim values (0 − 100) are for reference only . Adjustment normally needed if wire feed speed or type of weld joint is changed.[...]

  • Page 30

    OM-188 304 Page 26 5-8. How Manual Pulsed MIG W aveform Components Affect Arc And Burn-Off Rate[...]

  • Page 31

    OM-188 304 Page 27 SECTION 6 − PROGRAMS . Synergic Information: The manufacturer makes no warranties, express or implied, that welds made using the synergic parameters of this eq uip- ment will meet the requirements of the application. Th e synergic parameters contained in this equipment are intended only to be a general guideline. The choice and[...]

  • Page 32

    OM-188 304 Page 28 Program 2 −− .045 ER70S − 3 Mild Steel −− Recommended Gases: Argon/CO 2 Gas: Argon/CO 2 mixes up to 10% CO 2 ; Argon/O 2 mixes up to 5% O 2 IPM T rim Peak Amp Background Amp Freq. Pulse Width Starting Amps 80 0 323 48 56 2.20 498 127 10 342 61 91 2.28 529 174 20 370 84 108 2.38 529 221 30 388 95 134 2.53 529 268 40 390 [...]

  • Page 33

    OM-188 304 Page 29 Program 5 −− .035 Aluminum 4043 −− Argon IPM T rim Peak Amp Background Amp Freq. Pulse Width Starting Amps 140 0 194 29 60 1.10 400 213 10 196 53 76 1.15 501 286 20 205 80 98 1.20 529 359 30 249 103 109 1.35 529 432 40 272 134 11 8 1.50 529 505 50 298 150 125 1.70 529 578 60 320 170 135 1.90 529 651 70 340 191 145 2.10 52[...]

  • Page 34

    OM-188 304 Page 30 Program 8 −− .047 Aluminum 5356 −− Argon IPM T rim Peak Amp Background Amp Freq. Pulse Width Starting Amps 140 0 274 45 50 1.30 529 199 10 280 73 60 1.40 529 258 20 294 95 70 1.60 529 317 30 310 111 95 1.85 529 376 40 323 122 107 2.10 529 435 50 337 141 11 6 2.30 529 494 60 349 155 129 2.50 529 553 70 359 175 140 2.70 529[...]

  • Page 35

    OM-188 304 Page 31 Program 1 1 −− .045 Metal Core −− Recommended Gases: Argon/CO 2 Gas: Argon/CO 2 mixes up to 20% CO 2 IPM T rim Peak Amp Background Amp Freq. Pulse Width Starting Amps 100 0 310 45 50 2.30 529 145 10 330 61 65 2.45 529 190 20 354 70 90 2.55 529 235 30 365 78 11 0 2.65 529 280 40 370 89 130 2.75 529 325 50 376 100 150 2.85 [...]

  • Page 36

    OM-188 304 Page 32 SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance ! 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 Tighten W e[...]

  • Page 37

    OM-188 304 Page 33 7-3. V oltmeter/Ammeter Help Displays . Al l directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. 1 Help 0 Display Indicates a shorted thermistor RT2 on the left side of the unit. If this display is shown, con- tact a Factory Authorized Service Agent. 2 Help 1 Display Indic[...]

  • Page 38

    OM-188 304 Page 34 7-4. Error Codes 1 Program CRC Error 2 Program Range Error If either error code appears, reset th e display to factory settings as fol- lows: Press Parameter Select push but- ton or turn welding power source Of f and back On. Change settings and continue. ER R O R P r o g r am CRC Memo r y W i l l B e R e s e t Pr ess P a r m . S[...]

  • Page 39

    OM-188 304 Page 35 Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.weldin g .or g Star t Y our Professional W eldin g Career Now![...]

  • Page 40

    OM-188 304 Page 36 SECTION 8 − ELECTRICAL DIAGRAM 197 556-B Figure 8-1. Circuit Diagram For W elding Power Source (230/460 V olt Models)[...]

  • Page 41

    OM-188 304 Page 37 206 283-A Figure 8-2. Circuit Diagram For W elding Power Source (460/575 V olt Models)[...]

  • Page 42

    OM − 188 304 Page 38 SECTION 9 − PARTS LIST . Hardware is common and not available unless listed. 802 166-K 1 2 3 11 10 9 12 12 9 6 7 8 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 11 46 47 48 49 50 51 52 53 54 57 58 59 60 61 62 23 63 64 65 66 55 56 67 68 29 4 5 Figure 9-1. Parts Assembly[...]

  • Page 43

    OM-188 304 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Parts Assembly Quantity 1 +175 148 Wrapper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 551 Insulator , Side Lh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 44

    OM − 188 304 Page 40 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Parts Assembly (continued) Quantity 38 PC2 +212 210 Circuit Card Assy , Interconnecting W/Cmpnts (230/460) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 PC2 +208 783 Circuit Card, Interconnect (460/575) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 45

    Notes 229895 MA TERIAL THICKNESS GAUGE[...]

  • Page 46

    Notes W or k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginning of this manual .[...]

  • Page 47

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our 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 expe[...]

  • Page 48

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wor ks Comp any 1635 W es t Spencer S treet Applet on, WI 54914 USA International He adquarters − US A USA Phone: 920-735-4505 A uto-At tended USA & Canada FAX: 920-735-4134 Int ernational F A X: 920-735-4125 European Headqua rters − Unit[...]