Miller AlumaPower 450 MPa Owner'S Manual Download

Page: 1 / 48

File: MIG (GMAW)

Arc Welding Power Source

AlumaPower 450 MPa

OM-257219R

2016−10

Processes

Description

MIG (GMAW) Welding

Pulsed MIG (GMAW-P)

™

(400 Volt Model) CE

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

Summary of Contents for AlumaPower 450 MPa

Page 1: ...Welding Power Source AlumaPower 450 MPa OM 257219R 2016 10 Processes Description MIG GMAW Welding Pulsed MIG GMAW P 400 Volt Model CE For product information Owner s Manual translations and more visit www MillerWelds com ...

Page 2: ...ontinue 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 the most out of your Miller products 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 operati...

Page 3: ... 1 Features And Benefits 13 4 2 Arc Controls 13 4 3 Serial Number And Rating Label Location 13 4 4 Unit Specifications 13 4 5 Dimensions and Weight 13 4 6 Environmental Specifications 14 4 7 Duty Cycle and Overheating 15 4 8 Static Output Characteristics 15 SECTION 5 INSTALLATION 16 5 1 Selecting A Location 16 5 2 Selecting Cable Sizes 17 5 3 Weld Output Terminals 17 5 4 Connecting Weld Output Cab...

Page 4: ...tine Maintenance 33 8 2 Blowing Out Inside Of Unit 33 8 3 Removing Case and Measuring Input Capacitor Voltage In 400 VAC Models 34 8 4 Help Displays 35 8 5 Troubleshooting 35 SECTION 9 ELECTRICAL DIAGRAM 36 WARRANTY COMPLETE PARTS LIST Available at www MillerWelds com ...

Page 5: ... 400V W AUX POWER CE 907526 Council Directives 2006 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment Standards IEC 60974 1 2012 Arc welding equipment Part 1 Welding power sources IEC 60974 10 2007 Arc welding equipment Part 10 Electromagnetic compatibility EMC requirements Signatory ...

Page 6: ...til setting options welding programs are 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 is below the Exposure Limit Values ELVs n a YES NO for sensory effects at the standardized configurations if applicable and NO specific measures are needed Oc...

Page 7: ...kneeling 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 constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not wor...

Page 8: ...pared 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 close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw frozen pipes D...

Page 9: ...TS 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 maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels an...

Page 10: ...FPA 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 Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there...

Page 11: ...ement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol Dans ces conditions utiliser les équipements suivants dans l ordre indiqué 1 un poste à souder DC à tension constante à fil 2 un...

Page 12: ... des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflammables à une distance de 10 7 m de l arc de soudage En cas d impossibilité les recouvrir soigneusementavec des p...

Page 13: ... appareil D Tenir l équipement câbles et cordons à distance des véhicules mobiles lors de toute opération en hauteur D Suivre les consignes du Manuel des applications pour l équation de levage NIOSH révisée Publication Nº94 110 lors du levage manuelle de pièces ou équipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L ÉQUIPEMENT D Prévoir une période de refroidissement res pecter le cycle opérato...

Page 14: ...al ihs com National 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 Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allie...

Page 15: ...distributor for further information Safe37 2012 05 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2012 05 Protect yourself from electric shock 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 o...

Page 16: ...ervicing unit Safe27 2012 05 Always wear long sleeves and button your collar when servicing unit Safe28 2012 05 After taking proper precautions as shown connect power to unit Safe29 2012 05 Do not use one handle to lift or support unit Safe31 2012 05 V A Consult rating label for input power requirements Safe34 2012 05 Become trained and read the instructions before working on machine Safe35 2012 0...

Page 17: ...kasd lk Kasjf laksf lkasdf l aksdf lkasd flksadflkasd lk Become trained and read the instructions before working on the machine or welding Safe40 2012 05 5min V V V Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes after power is turned off before working on unit OR check input capacitor voltage and be sure it is nea...

Page 18: ...rc Operation GTAW Panel Remote Negative Inductance Foot Control Gas Metal Arc Welding GMAW U2 Conventional Load Voltage I2 Rated Welding Current Single Phase Circuit Breaker Gas Tungsten Arc Welding Positive Shielded Metal Arc Welding SMAW U1 Primary Voltage IP Degree Of Protection Lift Arc Trigger Hold Operation GTAW I1eff Maximum Effec tive Supply Cur rent Constant Voltage Output Off Direct Curr...

Page 19: ...fluidity in MIG Welding Mode see Section 7 2 SharpArct optimizes the size and shape of the arc cone bead width and appearance and puddle fluidity in Pulsed MIG Welding Mode see Section 7 4 4 3 Serial Number And Rating Label Location The serial number and rating information for this product is located on the rear panel Use rating label to determine input power requirements and or rated output For f...

Page 20: ...re by consultation with the distribution network operator if necessary that the system impedance complies with the impedance restrictions ce emc 1 2014 07 C China EEP Hazardous Substance Information 质量 China EEP Hazardous Substance Information 部 ComponentName 适 if applicable 质 Hazardous Substance 铅 Pb Hg 镉 Cd 铬 Cr6 苯 PBB 苯醚 PBDE 黄铜铜部 Brass and Copper Parts X O O O O O 装 Coupling Devices X O O O ...

Page 21: ...ating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 SA 181 560 250 541 A Continuous Welding 100 Duty Cycle At 450 Amperes 60 Duty Cycle At 580 Amperes 6 Minutes Welding 4 Minutes Resting 4 8 Static Output Characteristics The static output characteristics of the welding power source can be described as flat during the GMAW process and drooping during the SMAW and GTAW processes Static characteri...

Page 22: ...1 or CEC Section 20 1 Lifting Forks 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 4 Line Disconnect Device Locate unit near correct input power supply 5 1 Selecting A Location 4 18 in 460 mm 18 in 460 mm OR 1 Movement Location And Airflow 2 3 2 Do not move or operate unit where it could tip loc_med 2015 04 N...

Page 23: ... 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 500 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x3 0 3x95 600 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x4 0 3x120 3x4 0 3x120 This chart is a general guideline and m...

Page 24: ...n Tools Needed 3 4 in 19 mm 4 2 3 Do not place anything between Incorrect Installation 1 weld cable terminal and copper bar 5 5 Remote 14 Receptacle Information A J B K I C L N H D M G E F Ref 277764 A Socket Socket Information 24 VOLTS AC A 24 volts AC Protected by supplementary protect or CB2 B Contact closure to A completes 24 volts AC con tactor control circuit REMOTE CONTROL C Output to remot...

Page 25: ... Receptacle And Supplementary Protectors Ref 257348 B 1 115 V 7 Amp AC Receptacle 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects duplex receptacle CB2 protects 24 volts AC portion of Remote 14 receptacle from overload Press button to reset supplement ary protector 2 3 1 Notes ...

Page 26: ...the receptacle or conductor rating to be less than the rating of the circuit protection device All components of the circuit must be physically compatible See NEC articles 210 21 630 11 and 630 12 50 60 Hz Three Phase Input Voltage V 380 400 Input Amperes A At Rated Output 31 8 29 8 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 35 35 Normal Operating 3 45 45 Min Input Conductor Si...

Page 27: ... A complete Parts List is available at www MillerWelds com OM 257219 Page 21 Notes ...

Page 28: ...s List is available at www MillerWelds com OM 257219 Page 22 5 8 Connecting Input Power Tools Needed 5 16 in 3 8 1 4 9 7 10 11 L1 L2 L3 GND PE Earth Ground 1 Input5 2013 04 Ref 803 766 C 257 348 A 2 4 3 6 5 7 L1 L2 L3 ...

Page 29: ...hine Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief Tighten strain relief 3 Welding Power Source Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to machine grounding terminal first 5 Input Filter Board 6 Welding Power Source Line Terminals 7 Input Conductors L1 L2 L3 Con...

Page 30: ...play The meters display the actual weld output values after arc initiation and remains dis played for approximately three seconds after the arc is broken 5 Adjust Control 6 Volts Indicator 7 Arc Length Indicator 8 Amps Indicator 9 Setup Indicator 10 Process Indicator 11 Arc Control Indicator 12 Power Switch 13 Remote PC Interface 14 Setup Button 15 Wire Gas Indicator 16 Weld Output Terminal 17 Wel...

Page 31: ... features for desired operation To enter the Configuration Option Menu hold the Setup Button down during power up while the unit is displaying 8888 on the Left and Right Displays SET UP will be displayed momentarily Configurationoptions are displayed in the Left Display Settings are displayed in the Right Display Settings can be changed by turning the Adjust Control If a setting does not change wh...

Page 32: ...This option allows adjusting the Pulsed MIG pro cess in units of Arc Length PULS ARCL or preset voltage PULS VOLT In PULS AUTO operation adjustments can only be made in units of arc length Wire Feed Speed And Wire Diameter Units WFS IPM WFS is displayed in inches per minute Diameter is displayed in inches WFS MPM WFS is displayed in meters per minute Diameter is displayed in millimeters Revision I...

Page 33: ...For Remote Control Feeder GMAW GMAW P Process Ref 277770 A Turn off power before making connections 1 Remote 14 Receptacle 2 Positive Weld Output Terminal 3 Negative Weld Output Terminal 4 Ground Cable to Workpiece 5 Workpiece 6 Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder Use of shielding gas is dependant on Wire Type 3 4 5 6 7 8 9 1 2 6 ...

Page 34: ...being used Refer to the MIG Wire and Gas Selection Table for available wires and gases see Section 7 3 Operation While the Volts Indicator is lit under the Left Display the Adjust Control is used to set desired preset voltage The preset voltage can be adjusted re motely at the wire feeder if the feeder has a voltage control This voltage con trol will override the Adjust Control of preset voltage o...

Page 35: ...TYPE DEFAULT INDUCTANCE Aluminum 035 0 9 AL4X 4000 Series 040 1 0 AL4X 4000 Series 3 64 1 2 AL4X 4000 Series 1 16 1 6 AL4X 4000 Series 035 0 9 AL5X 5000 Series 040 1 0 AL5X 5000 Series 3 64 1 2 AL5X 5000 Series 1 16 1 6 AL5X 5000 Series ARGN ARGON 25 Wire diameter in inches mm Refer to section 6 2 to change displayed units Notes ...

Page 36: ...ing arc cone Lower settings widen the arc cone increases puddle fluidity and flat tens the weld bead appearance Higher settings narrow the arc cone re duces puddle fluidity and crowns the weld bead appearance Each Wire and Gas Type combination has independent Arc Length and Shar pArc settings These settings are pre served when the unit is turned off Arc Length Pulse MIG Manual Control see Section ...

Page 37: ...Series ARGN ARGON 035 0 9 AL49 4943 040 1 0 AL49 4943 3 64 1 2 AL49 4943 1 16 1 6 AL49 4943 035 0 9 AL5X 5000 Series 040 1 0 AL5X 5000 Series 3 64 1 2 AL5X 5000 Series 1 16 1 6 AL5X 5000 Series ARGN ARGON HE AR25 HELIUM ARGON Wire diameter in inches mm Refer to section 6 2 to change displayed units Other normal gas mixtures can be used by adjusting arc length and sharp arc Use the program closest ...

Page 38: ... process can only be changed at the wire feeder Power Source Display Wire Feeder with Remote Process Select Detected and Set for Pulsed MIG When the power source Right Display is PULS a Remote Process Select wire feeder is detected and is set for Pulsed MIG opera tion The active weld process can only be changed at the wire feeder Using a Dual Wire Feeder with Remote Process Select When using a dua...

Page 39: ...wer before maintaining 3 Months Replace Damaged Or Unreadable Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections 6 Months Blow Out Inside 8 2 Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown Ref 277764 A ...

Page 40: ...oltage across the screw terminals on PC2 as shown until voltage drops to near 0 zero volts If the capacitor voltage does not drop to near zero after sev eral minutes use a bleeder re sistor of between 25 and 1000 ohms at least 5 watts 16 AWG 1000 volts DC insulating rating wire to discharge the ca pacitor s 4 Typical Bleeder Resistor An example of a typical bleeder re sistor is shown on this page ...

Page 41: ...ndicates a malfunction in the secondary power circuit of the unit If this display is shown contact a Factory Authorized Service Agent Help 25 Display Indicates machine has reached Duty Cycle limit See Section 4 7 Unit must be left on to power the fan for cooling Duty Cycle limit will automaticallyreset when unit has cooled HE L P 1 P 2 P 3 P 5 P 6 P 8 HE L HE L HE L HE L HE L P25 HE L 8 5 Troubles...

Page 42: ...OM 257219 Page 36 SECTION 9 ELECTRICAL DIAGRAM Figure 9 1 Circuit Diagram ...

Page 43: ...OM 257219 Page 37 253 463 C ...

Page 44: ...Notes ...

Page 45: ...Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now ...

Page 46: ...Notes ...

Page 47: ...uns 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 such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine d...

Page 48: ...h 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 Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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