Instruction/ maintenance manual of the product 400 Miller Electric
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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 Fee.
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 dont have time to do it any other way. Thats why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
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.
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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.
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.
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.
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.
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.
LES RAVONS DE LARC peuvent pro voquer des brlures dans les yeux et sur Ia peau. Le rayonnement de larc 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.
1 -3. Dangers supplØmentaires en relation avec linstallation, le fonctionnØrnent et Ia maintenance Risque DJNCENDIE OU DEXPLOSION. Ne pas placer lappareil sur, au-dessus ou a proximitØ de surfaces infilammables.
1-4. Principales normes de sØcuritØ Safety in Welding and Cutting, norme ANSI Z49. 1, de IAmerican 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.
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.
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.
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.
2-7. Remote 14 Receptacle Argon Gas ORQ Typical flow rate is .57 cmh (cubic meters per hour). Check wire man ufacturers 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.
2-9. Installing Wire Spool and Adjusting Hub Tension OM-189 424 Page 13.
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.
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).
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.
3-1. Controls SECTION 3 OPERATION OM-189 424 Page 17.
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.
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.
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).
SECTION 5- ELECTRICAL DIAGRAM Figure 5-1. Circuit Diagram SD-I 89 410 OM-189 424 Page 21.
SECTION 6- PARTS LIST Figure 6-1. Main Assembly ST-802 104 a, Hardware is common and not available unless listed. 0 a, cJ (0 U- / / / / cJ (I (0 LL U) c~) (0 ci, U- (0 OM-1 89424 Page 22.
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 .
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~) cJ (0 C 0) 0 C Cj C CJ U Co OM-1 89 424 Page 24.
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.
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 .
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.
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).
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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.
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 lntematton.
An important point after buying a device Miller Electric 400 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric 400 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric 400 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric 400 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric 400 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric 400, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric 400.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric 400. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric 400 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
