Miller Auto-Continuum 350 Owner'S Manual Download Page 1

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Processes

OM-273473D

2016−11

Auto−Continuum

350 And 500

w/ Insight Core

Processes

Description

Arc Welding Power Source

Air Carbon Arc (CAC-A)
Cutting and Gouging

File: Advanced Manufacturing Systems

MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

Summary of Contents for Auto-Continuum 350

Page 1: ...Processes Description Arc Welding Power Source Air Carbon Arc CAC A Cutting and Gouging File Advanced Manufacturing Systems MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding For product info...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...4 3 500 Model Specifications 12 4 4 Dimensions And Weight 13 4 5 Environmental Specifications 13 4 6 Static Characteristics 13 4 7 Duty Cycle And Overheating 14 SECTION 5 INSTALLATION 15 5 1 Selectin...

Page 4: ...Web Pages 40 8 2 Home Screen 40 8 3 Setup Screen 41 8 4 Arc Management Screen 42 8 5 Data Management Screen 43 8 6 Help Screen 43 SECTION 9 MAINTENANCE TROUBLESHOOTING 44 9 1 Routine Maintenance 44 9...

Page 5: ...neeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC...

Page 6: ...ared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as clo...

Page 7: ...S can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for ma...

Page 8: ...PA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of...

Page 9: ...s dans un environnement humideou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y...

Page 10: ...br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage v rifier et s assur...

Page 11: ...areil D Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur D Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e P...

Page 12: ...ational Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cy...

Page 13: ...ck by insulating yourself from work and ground Safe3 2012 05 Disconnect input plug or power before working on machine Safe5 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation...

Page 14: ...t discard product with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collection facility Contact your local recycling office or your local...

Page 15: ...nt Three Phase Static Frequency Converter Transfor mer Rectifier U1 Primary Voltage IP Degree Of Protection S Suitable for Some Hazardous Locations I1eff Maximum Effective Supply Current Constant Curr...

Page 16: ...Three Phase 350 A 34 V DC 100 Duty Cycle 10 44 V 20 400 A 75 36 7 0 1A 21 8 0 1A 20 8 0 1A 18 8 0 1A 14 6 0 1A 14 4 0 8 13 8 0 17 While idling Input amperage fluctuates while idling and is always less...

Page 17: ...IP23S This equipment is designed for outdoor use It may be stored but is not intended to be used for welding outside during precipitation unless sheltered IP23S 2014 06 B Temperature Specifications O...

Page 18: ...ge or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty 5 Minutes Welding 5 Minutes Resting Overheating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 SA 268 49...

Page 19: ...2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Hand Cart Use cart or similar device to move unit 4 Line Disconnect De...

Page 20: ...00 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 6...

Page 21: ...are clean 1 Negative Output Terminal 2 Positive Output Terminal 3 Correct Weld Cable Connection For Single Feeder 4 Correct Weld Cable Connection For 2 0 And Larger Double Cables 5 Incorrect Weld Cab...

Page 22: ...J Socket Socket Information A 50 Volts DC Common B 50 Volts DC Common C Voltage Sense D 50 Volts DC Power E 50 Volts DC Power F ENET Rx G ENET Tx H Drain I ENET Tx J ENET Rx 5 5 Volt Sense Receptacle...

Page 23: ...nication Panel And E Stop 1 Ethernet Receptacle Used for connecting a computer di rectly to the power source to ac cess configuration web pages 2 Ethernet Receptacle Used for connecting a robot direct...

Page 24: ...AC receptacle Press button to reset breaker If breaker continues to open contact a Factory Authorized Service Agent Ref 907641 TP1 907657 tp2 2 1 5 9 Devicenet Receptacle Ref 277971 A A B C D E Socke...

Page 25: ...3 Max Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses 2 50 30 30 25 20 Normal Operating Fuses 3 70 40 35 30 25 Min Input Conductor Size In AWG 4 8 10 12 12 14 Max Recommended Input Condu...

Page 26: ...11 Connecting 3 Phase Input Power input5 2013 04 274300 B 259119 C Tools Needed Side View Of Unit Input Power Contactor Connections 3 8 in 3 16 in 2 3 7 1 8 4 10 9 GND PE Earth Ground L1 L2 L3 6 3 L2...

Page 27: ...Connections 2 Strain Relief Kit 274 563 Supplied With Machine Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief Tighten strain relief 3 Wel...

Page 28: ...ance with a standard welding circuit connection The length of a welding circuit is determinedas follows Welding Circuit Electrode Cable Length ECL Work Cable Length WCL Workpiece Length WL See Section...

Page 29: ...oltage drop in all semi automatic processes when the Vsense option is On The work sense lead connects to the Axcess welding power source 4 pin connector located above the negative output terminal This...

Page 30: ...ion of a welding arc from its normal path due to magnetic forces It will adversely affect the appearance of a weld cause excessive spatter and impair the quality of a weld Arc blow occurs primarily du...

Page 31: ...leads being directly in the current flow path of the welding arc Interaction between welding circuits will affect voltage drop in the workpiece The voltage drop across the workpiece will not be measu...

Page 32: ...ce This arrangement is a better setup for supporting separate voltage feedback to the welding power sources The most accurate voltage sensing may not be achieved due to voltage drops in the workpiece...

Page 33: ...ng Lead 6 Robot 7 Workpiece This arrangement is the best setup for proper voltage sensing at the workpiece Voltage feedback to the welding power sources will more accurate and result in reliable arc s...

Page 34: ...arth Ground Being Measured 100W Light Bulb 110 Volts AC Neutral 1 Volt 1 W V Measuring Facility Earth Ground Resistance The resistance of an earth ground can be measured using a 100W light bulb an ac...

Page 35: ...g Conduit Isolate It From Robot Control Cabinet Existing Input Power Supply Ground Make Ground Lead 5 ft 1 5 m To 10 ft 3 m Longer And Coil It Inside Robot Control 10 ft 3 m Minimum Work Weld Cable Wo...

Page 36: ...ousing S Check gun connection at wire drive and be sure O rings seal at drive housing S Check condition of gas diffuser S Check condition of nozzle S Check O ring for proper sealing at nozzle Welding...

Page 37: ...al around the arc a condition that normally exists when welding is performed near the end of ferromagneticmaterials Although arc blow cannot always be completely eliminated it can be controlled or red...

Page 38: ...e rolls Replace with proper size drive rolls Too much or too little drive roll pressure Adjust drive roll pressure Too much tension set at wire spool Reduce wire spool tension Restriction in unspooler...

Page 39: ...k distance Incorrect gun or torch angle Set proper gun angle porosity or dirty welds mean gun angle is too large Nozzle restriction Clean off spatter or remove restriction Breeze or drafts in weld zon...

Page 40: ...replace voltage sense leads High frequency noise in the area Be sure proper grounding methods are followed when TIG or plasma equipment is used in the area Arc blow See Section 6 7 Drive motor tachome...

Page 41: ...Allow unit to cool to operating temperature Er ror LED will turn off and welding may resume Blinking A system error has occurred Use the User Interface to determine the source of the error as well as...

Page 42: ...OM 273473 Page 38 7 2 User Interface Ref 266 061 B 2 1 5 6 7 8 4 16 9 10 11 3 20 12 13 14 15 17 19 18...

Page 43: ...he process selected 9 Amperage Wire Feed Speed Material Thickness Adjustment Knob Use this knob to increase decrease amper age wire feed speed or material thickness depending on the process selection...

Page 44: ...Power Source Information Displays power source information Edit but ton allows these parameters to be changed 4 Active Program Displays the program number process wire size and alloy and gas Edit butt...

Page 45: ...ed 7 Region Displays current region Edit button allows re gion to be changed 8 Status Displays the status of Insight software Edit button allows that status to be changed 9 WiFi Settings Edit button a...

Page 46: ...ill vary Edit button allows parameters to be changed 3 Weld Sequence Displays active weld sequence parameters Edit button allows changes to these parame ters 4 Lock Status Displays the current status...

Page 47: ...error experienced by the system View button displays a list of previous errors and the time at which they occurred 5 System Log Displays the last entry into the system log View button displays a list...

Page 48: ...be done by Factory Authorized Service Agent Reference Every 3 Months l Unreadable Labels Weld Terminals nl Weld Cables nl Gun Cables nl Cords nl Cracked Parts Weld Connections n Tighten Weld Cable Co...

Page 49: ...e addressed before contin uing use MESSAGE No fault has occurred but some action must be taken before resum ing use of the welding system For instance input power may need to be cycled after loading n...

Page 50: ...Gas Flow Error ERR COOL FLW ERROR No coolant flow in water system Check water cooling system Coolant Flow Error ERR GND CRNT ERROR Weld current detected in earth ground Check and repair feeder weld c...

Page 51: ...n the power source AUX Voltage Low Error UNUSED 230 ERROR Unused Error 230 Cycle power on the power source Unused Error 230 ERR THERM 1 ERROR Thermistor 1 overtemp Allow welder to cool then cy cle pow...

Page 52: ...ror ERR PWR SRC ERROR Boost precharge error Cycle power on the power source Boost Precharge Error ERR PWR SRC ERROR Boost bus balance error Cycle power on the power source Boost Bus Balance Error ERR...

Page 53: ...protector CB1 and reset if necessary Check motor control cable connections Wire feeds erratically Readjust hub tension Readjust drive roll pressure Clean or replace dirty or worn drive rolls Remove we...

Page 54: ...OM 273473 Page 50 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For Auto Contiuum 350 Model Page 1 of 2...

Page 55: ...OM 273473 Page 51 273 905 B...

Page 56: ...OM 273473 Page 52 Figure 10 2 Circuit Diagram For Auto Continuum 350 Model Page 2 of 2...

Page 57: ...OM 273473 Page 53 273 905 B...

Page 58: ...OM 273473 Page 54 Figure 10 3 Circuit Diagram For Auto Contiuum 500 Model Page 1 of 2...

Page 59: ...OM 273473 Page 55 273 490 B...

Page 60: ...OM 273473 Page 56 Figure 10 4 Circuit Diagram For Auto Continuum 500 Model Page 2 of 2...

Page 61: ...OM 273473 Page 57 273 490 B...

Page 62: ...SECTION 11 PARTS LIST FOR 350 AND 500 MODELS Figure 11 2 Figure 11 3 Figure 11 4 Figure 11 5 Figure 11 6 Figure 11 7 8 3 9 4 1 5 12 15 16 17 18 2 7 14 274585 B 10 21 21 22 23 13 24 19 6 11 20 Figure 1...

Page 63: ...l Rh W Cmpnts 1 1 15 Figure 11 3 Windtunnel Lh W Cmpnts 1 1 16 PC1 248915 Circuit Card Assy Input 1 1 17 PC4 273420 Circuit Card Assy Inverter Arc Control Auto W Prog 1 1 18 PC14 265925 Circuit Card A...

Page 64: ...tand off Insul 250 20 X 1 250 Lg X 437 Thd 2 2 10 236727 Insulator Heat Sink 1 1 11 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole Cent 2 2 12 253547 Bus Bar Xfmr Current 1 1 13 245520 Bushing S...

Page 65: ...oost 2 4 6 252449 Thermistor Ntc 30k Ohm 25 Deg C 8 00in Lead 1 1 7 173632 Thermistor Ntc 30k Ohm 25 Deg C 12 00in Lead 1 1 8 262497 Stand off Support PC Card 156 Dia W P L 1 125 1 1 9 153403 Bushing...

Page 66: ...378 Mtg Holes 2 3 HD1 168829 Transducer Current 1000a Module Max Open Loop 1 4 245520 Bushing Snap in Nyl 1 062 Id X 1 500 Mtg Hole Cent 3 5 153403 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole Cent 2 W...

Page 67: ...OM 273473 Page 63 Notes...

Page 68: ...OM 273473 Page 64 Hardware is common and not available unless listed 274588A 3 9 4 12 6 14 1 7 16 18 17 11 19 13 23 2 8 21 15 5 20 22 10 24 Figure 11 5 Front Panel Assembly...

Page 69: ...lted Rear Includes 1 18 252830 Terminal Pwr Output Front Bolted Rear Int Thread 1 11 186228 O ring 0 739 Id X 0 070 H 1 12 250037 Insulator Bulkhead Front 890 Od 1 13 185718 O ring 0 989 Id X 0 070 H...

Page 70: ...0 Ohm Faston Te 1 7 265261 Lift Eye Formed 2 266393 Label Warning Input Connections Electric Shock 1 8 266232 Lift Eye 1 9 256975 Seal Lift Eye 1 10 PC19 273411 Assy Communication Package Auto 1 11 26...

Page 71: ...08 Plugs W Leads 1 7 260822 Antenna Rf Monopole 2 4ghz Screw Mount 1 8 275563 Cable Assy Rj45 Male M12 Female 4m Lg 2 9 275313 Panel Rear Enet 1 269416 Label Ethernet Wireless 1 10 271543 Cable Assy R...

Page 72: ...Notes...

Page 73: ...Notes...

Page 74: ...Notes...

Page 75: ...ns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components suc...

Page 76: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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