Instruction/ maintenance manual of the product 456 CV Miller Electric
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OM-188 422F June 2001 Processes Description Arc Welding Power Source Multiprocess W elding R Phoenix 456 CC/CV (400 V olt Models) Visit our website at www.
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 .
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 . . . .
dec_con1 10/95 Declaration of Conformity For European Community (CE) Products Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W .
OM-188 422 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.
OM-188 422 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 of f 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.
OM-188 422 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.
OM-188 422 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects 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.
OM-188 422 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.
OM-188 422 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.
OM-188 422 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.
OM-188 422 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.
OM-188 422 Page 9 SECTION 2 – DEFINITIONS 2-1. Manufacturer ’ s W arning Label Definitions W arning! W atch 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.
OM-188 422 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.
OM-188 422 Page 1 1 2-2. Symbols And Definitions A Amperage Panel Alternating Current (AC) V V oltage Output Circuit Breaker Remote On Of f Gas Tungsten Arc W elding Negative V oltage Input Direct Cur.
OM-188 422 Page 12 2-3. Manufacturer ’ s Rating Label S-184 765 / S-184 763.
OM-188 422 Page 13 SECTION 3 – INST ALLA TION 3-1. Specifications Input Power Rated W elding Output Amperage Range V oltage Range Maximum Open- Circuit Amperes Input At Rated Load Output 60 Hz, Thre.
OM-188 422 Page 14 3-3. V olt-Ampere Curves 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. va_curve1 4/95 – SA-181 561 / SA-181 562 CC Modes CV Modes 3-4.
OM-188 422 Page 15 3-5. Selecting A Location loc_2 3/96 - ST -800 61 1 / ST-802 260 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.
OM-188 422 Page 16 3-6. 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 .
OM-188 422 Page 17 3-7. 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.
OM-188 422 Page 18 3-8. 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 3-7). 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.
OM-188 422 Page 19 3-10. Connecting Input Power ssb2.4* 1/94 – ST -801 523-B / ST -801 946 T ools Needed: 5/16 in Input Filter 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.
OM-188 422 Page 20 SECTION 4 – OPERA TION 4-1. Front Panel Controls 1 Power Switch . The fan motor is thermostatically controlled and only runs when cooling is needed.
OM-188 422 Page 21 4-2. 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 Lift-Arc T rigger Hold TIG (GT AW) VA Blank Preset Amps 85 TIG (GT AW) Blank Preset Amps VA 85 MIG (GMAW) Preset V olts Blank VA 24.
OM-188 422 Page 22 4-3. Mode Switch Settings The SMAW modes provide the Adaptive Hot Start feature, which automatically increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start.
OM-188 422 Page 23 4-4. Lift-Arc TIG Procedure With Mode switch in the Lift-Arc TIG position, start an arc as follows: 1 TIG Electrode 2 W orkpiece T ouch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds , and slowly lift electrode.
OM-188 422 Page 24 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
OM-188 422 Page 25 5-3. Removing Case and Measuring Input Capacitor V oltage Turn Of f welding power source, an d disconnect input power . 1 Outside Handle Screws T o loosen top, remove two outside handle screws from both handles and all side bolts.
OM-188 422 Page 26 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.
OM-188 422 Page 27 5-5. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative. Place line disconnect switch in On position (see Section 3-10). Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 3-10).
OM-188 422 Page 28 SECTION 6 – ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Welding Power Source.
OM-188 422 Page 29 192 795.
OM-188 422 Page 30 SECTION 7 – P ARTS LIST . Hardware is common and not available unless listed. 802 261-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 39 40 41 42 4 44 45 46 48 49 50 46 51 53 54 58 59 62 63 64 65 4 PC1 PC2 3 66 4 5 6 7 8 30 34 35 36 37 38 36 43 47 60 61 10 52 55 56 57 67 802 261 Figure 7-1.
OM-188 422 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly Quantity 1 187 234 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-188 422 Page 32 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly (Continued) Quantity 54 HD1 168 829 TRANSDUCER, current 1000A max 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 174 992 KNOB, pointer .
OM-188 422 Page 33 Notes.
OM-188 422 Page 34 Notes.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 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 .
PRINTED IN USA 2001 Miller Electric Mfg. Co. 1/01 Miller Elect ric Mfg. Co. An I l li noi s T ool W orks Company 1635 W est S pencer Street Applet on, W I 5 4914 USA International He adquarte rs .
An important point after buying a device Miller Electric 456 CV (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 456 CV 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 456 CV - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric 456 CV you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric 456 CV will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric 456 CV, 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 456 CV.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric 456 CV. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric 456 CV 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
