Miller MigMatic S400i Owner'S Manual Download Page 16 | Manualshive

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OM-287504 Page 10

3-7. Duty Cycle And Overheating

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. Reduce amperage or

voltage, or duty cycle before

welding.

NOTICE

−

Exceeding duty cycle

can damage unit and void

warranty.

6 Minutes Welding

4 Minutes Resting

Overheating

0

15

A or V

OR

Reduce Duty Cycle

Minutes

60% Duty Cycle

MigMatic S400i

MigMatic S400iP

MigMatic S500i

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Summary of Contents for MigMatic S400i

Page 1: ...ion MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source OM 287504A 2020 05 MigMatic S400i S400iP S500i CE File MIG GMAW Wire Feeder For product information Owner s Manual translations an...

Page 2: ...ducts Please take time to read the Safety Precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you...

Page 3: ...3 6 Environmental Specifications 9 3 7 Duty Cycle And Overheating 10 3 8 Volt Ampere Curves 11 SECTION 4 INSTALLATION 12 4 1 Selecting A Location 12 4 2 Selecting Cable Sizes 13 4 3 Weld Output Termi...

Page 4: ......

Page 5: ......

Page 6: ...changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational exposure...

Page 7: ...n any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions...

Page 8: ...If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that...

Page 9: ...rks to move unit be sure forks are long enough to extend beyond opposite side of unit Keep equipment cables and cords away from moving vehicles when working from an aerial location Follow the guidelin...

Page 10: ...te www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pam...

Page 11: ...tion Safe37 2017 04 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2017 04 Protect yourself from electric shock by insulating yourself from wo...

Page 12: ...power requirements See rating label on unit and check input voltage available at site Safe34 2012 05 Become trained and read the instructions and labels before working on machine Safe35 2012 05 Wear...

Page 13: ...2017 04 2 2 Miscellaneous Symbols And Definitions A Amperage V Volts Alternating Current AC Direct Current DC Remote On Off Protective Earth Ground Line Connection Three Phase Gas Metal Arc Welding G...

Page 14: ...end user as necessary based upon application specific requirements The end user is solely responsible for selection and coordination of appropriate equipment adoption or adjustment of default weld par...

Page 15: ...Electromagnetic Compatibility EMC This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There can be p...

Page 16: ...thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void...

Page 17: ...how the normal minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown MIGMATIC S400i MIGMATIC S400iP MIGMATIC S...

Page 18: ...2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input power supply 4 1...

Page 19: ...5 2x3 0 2x95 2x3 0 350 60 1 0 70 2 0 95 3 0 120 4 0 2x70 2x2 0 2x95 2x3 0 2x95 2x3 0 2x120 2x4 0 400 60 1 0 70 2 0 95 3 0 120 4 0 2x70 2x2 0 2x95 2x3 0 2x120 2x4 0 2x120 2x4 0 500 70 2 0 95 3 0 120 4...

Page 20: ...rt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose be...

Page 21: ...ght hand BSP threads Obtain and install gas hose 4 Gas In Fitting 5 Gas Out Fitting The Gas In and Gas Out fittings have 1 4 right hand BSP male threads Obtain proper size type and length hose and mak...

Page 22: ...56172374_6 A 2 3 1 4 7 7 Pin Receptacle Information 956172374_10 A REMOTE 7 PIN Socket Socket Information AWC CONTROL 1 Common 2 Automatic Water Cooler Control 3 Not Used 4 Automatic Water Cooler Prot...

Page 23: ...See Section 4 10 Provides 42 volts AC to power wire feeder and signal communication to feeder 5 Cable Positive Connect to weld output terminal for MIG welding lo cated on the rear panel of the weldin...

Page 24: ...remote control M 0 volts AC output remote control N 0 volts AC output remote control Communication G Chassis common A Data reception serial gate B Common communication serial gate C Data transmissions...

Page 25: ...lding Power Source 3 Wire Feeder 4 Gas Cylinder 5 Gas Hose 6 Wire Feeder Cable See Section 4 9 7 Welding Gun Connect to welding torch connector in wire feeder 8 Work Lead Connect work lead to negative...

Page 26: ...ve Supply Current I1eff A 23 2 23 2 27 2 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 Normal Operating Fuses 3 30 35 30 35 45 50 Maximum Recommended Supply Conductor Length In...

Page 27: ...OM 287504 Page 21 4 13 Connecting 3 Phase Input Power input2 2012 05 Ref 803766 C Ref 956172374_9_A GND PE Earth Ground L1 2 1 L2 L3 3 3 4 5 6 7 Tools Needed...

Page 28: ...Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L...

Page 29: ...icator Light LED illuminates when input power is on 6 High Temperature Light Light comes on if unit overheats Welding can resume when unit has cooled see Section 5 2 7 Gas Out 1 4 BSP Fitting 8 14 Pin...

Page 30: ...ne by Factory Authorized Service Agent Every 3 Months Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables Every 3 Months Cables And Cords Every 3 Months Clean And Tighten Weld Connectio...

Page 31: ...see Section 4 13 No weld output Input voltage outside acceptable range of variation see Section 4 12 4 13 Check repair or replace remote control Unit overheated Allow unit to cool with fan on see Sect...

Page 32: ...OM 287504 Page 26 SECTION 7 ELECTRICAL DIAGRAMS PC2 PC2 PC4 PC7 FM FM FM FM Figure 7 1 Circuit Diagram for Migmatic S400i...

Page 33: ...OM 287504 Page 27 956172379 A PC5 PC5 HD1 HD2 PC1 PC8...

Page 34: ...OM 287504 Page 28 PC2 PC2 PC4 PC7 FM FM FM FM Figure 7 2 Circuit Diagram for Migmatic S400iP...

Page 35: ...OM 287504 Page 29 956172380 A PC5 PC5 PC1 PC8 HD2 HD1...

Page 36: ...OM 287504 Page 30 PC4 PC7 PC2 PC2 FM FM FM FM Figure 7 3 Circuit Diagram for Migmatic S500i...

Page 37: ...OM 287504 Page 31 956172381 A PC1 PC5 PC5 HD1 HD2 PC8...

Page 38: ...tion Part No Item No Figure 8 1 Main Assembly MigMatic S400i 400iP 500i Quantity Dia Mkgs 1 056076323 Receptacle Twist Lock Power 2 2 156007048 Cover 65 x 27 1 3 116170004 Grid Front 2 4 056052017 Ins...

Page 39: ...057084229 Circuit Board Driver 2 34 156005230 Support Heatsink 1 35 056082110 Heatsink 1 36 156005231 Support Circuit Board 4 37 156122104 Panel Right Side 1 38 156121052 Cover 1 39 PC7 057084230 Cir...

Page 40: ...Notes Securely connect work clamp to a clean area close to the weld joint Welding Tip...

Page 41: ...Notes...

Page 42: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 43: ...sma Cutting Torches No Labor Induction Heating Power Sources Coolers NOTE Digital Recorders are Warranted Separately by the Manufacturer Load Banks Motor Driven Guns except Spoolmate Spoolguns PAPR Bl...

Page 44: ...Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumable...

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