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OM-185 648F

July 2001

Processes

Description

MIG (GMAW) Welding

With Optional Equipment:
Pulsed MIG (GMAW-P)

Arc Welding Power Source

Invision 456P

Visit our website at

www.MillerWelds.com

Содержание INVISION Invision 456P

Страница 1: ...OM 185 648F July 2001 Processes Description MIG GMAW Welding With Optional Equipment Pulsed MIG GMAW P Arc Welding Power Source Invision 456P Visit our website at www MillerWelds com ...

Страница 2: ...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 operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit...

Страница 3: ...l 11 SECTION 3 INSTALLATION 12 3 1 Specifications 12 3 2 Duty Cycle And Overheating 12 3 3 Volt Ampere Curve 13 3 4 Selecting A Location 14 3 5 Weld Output Terminals And Selecting Cable Sizes 15 3 6 Remote 14 Receptacle Information 16 3 7 115 Volts AC Duplex Receptacle 17 3 8 Electrical Service Guide 17 3 9 Connecting Input Power 18 SECTION 4 OPERATION 19 4 1 Front Panel Controls 19 4 2 Mode And V...

Страница 4: ...ry Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 December 1995 Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1989 Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements an...

Страница 5: ...or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do n...

Страница 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Страница 7: ... maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area i...

Страница 8: ... is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one s...

Страница 9: ...tion est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement ...

Страница 10: ...ct D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à...

Страница 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Страница 12: ...nétiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir ex aminé plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du National Re search Council a conclu L accumulation de p...

Страница 13: ...2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and in...

Страница 14: ...ng Watch Out There are possible hazards as shown by the symbols 2 When power is applied failed parts can explode or cause other parts to explode 3 Flying pieces of parts can cause injury Always wear a face shield when servicing unit 4 Always wear long sleeves and button your collar when servicing unit 5 After taking proper precautions as shown connect power to unit 4 96 1 2 3 4 5 S 179 309 A 60 1 ...

Страница 15: ... 648 Page 11 2 2 Symbols And Definitions A Amperage Positive Remote V Voltage Output Circuit Breaker Negative On Off Inductance Protective Earth Ground Voltage Input 2 3 Manufacturer s Rating Label S 184 765 ...

Страница 16: ...y Cycle And Overheating Duty Cycle is percentage of 10 min utes 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 duty cycle before welding Y Exceeding duty cycle can damage unit and void war ranty Overheating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 SA 181 560...

Страница 17: ...5 648 Page 13 3 3 Volt Ampere Curve va_curve1 4 95 SA 181 562 Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown ...

Страница 18: ...r device to move unit 4 Rating Label Use rating label to determine input power needs 5 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 26 in 660 mm 15 1 2 in 394 mm Movement 2 3 Location 5 Dimensions And Weight 18 in 460 mm 18 in 460 mm 118 lb 53 5 kg 4 Y D...

Страница 19: ...ing the work area Total Cable Copper Length In Weld Circuit Not Exceeding 100 ft 30 m Or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Weld Output Terminals Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2...

Страница 20: ... Contact closure to I completes 115 volts ac con tactor control circuit E F C Output to remote control 10 volts dc in MIG mode D Remote control circuit common REMOTE OUTPUT CONTROL E 0 to 10 volts dc input command signal from re mote control M Mode select N Remote inductance control A V AMPERAGE F Current feedback 1 volt dc per 100 amperes Ref ST 801 718 AMPERAGE VOLTAGE H Voltage feedback 1 volt ...

Страница 21: ...mote 14 receptacle from overload CB2 protects 24 volts ac portion of Remote 14 receptacle from overload Press button to reset breaker 2 3 1 3 8 Electrical Service Guide Input Voltage 400 Input Amperes At Rated Output 31 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 45 Min Input Conductor Size in AWG Kcmil 10 Max Recommended Input Conductor Length In Feet Meters 264 80 Min Grou...

Страница 22: ... 3 before proceeding Check input voltage available at site Remove left side panel 1 Input And Grounding Conductors See Section 3 8 Install ring terminals of proper size onto input conductors for connection to input filter board terminals see illustration 2 Line Disconnect Device Select type and size of overcurrent protec tion using Section 3 8 Connect input and groundingconductors to a deenergized...

Страница 23: ... unit defaults to standard MIG mode Pulsed MIG welding requires that an external pulsing control be con nected to the Remote 14 recep tacle The remote pendant controls whether the unit is in standard MIG or pulsed MIG mode When the pulsing control is disconnected the unit returns to standard MIG opera tion Voltage Control The unit defaults to Panel control of output voltage When a suitable re mote...

Страница 24: ... values for approximately three seconds after the arc is broken NOTE Mode Meter Reading At Idle Meter Reading While Welding MIG Preset Volts Blank V A 24 5 Actual Volts Actual Amps V A 24 5 250 Pulsed MIG Pulse Display Pulse Display V A PPP PPP Actual Volts Actual Amps V A 24 5 250 ...

Страница 25: ...nths 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 Terminals 6 Months Blow Out Inside 5 2 Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown ST 801 718 ...

Страница 26: ...Voltmeter Measure the dc voltage across the screw terminals on RC3 and RC5 as shown until voltage drops to near 0 zero volts Proceed with job inside unit Rein stall cover when finished Tools Needed 5 16 in Ref ST 801 718 ST 801 536 Y Significant DC voltage can remain on capacitors af ter unit is Off Always check the voltage as shown to be sure the input capacitors have discharged be fore working o...

Страница 27: ... shown contact a Factory Authorized Service Agent 5 Help 5 Display Indicates the right side of the unit has overheated The unit has shut down to allow the fan to cool it see Section 3 2 Operation will contin ue when the unit has cooled 6 Help 6 Display Indicates that the input voltage is too low and the unit has automati cally shut down Operation will con tinue when the voltage is within 15 of the...

Страница 28: ...tions see Section 3 9 No weld output meter display On Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 3 2 Erratic or improper weld output Use proper size and type of weld cable see Section 3 5 Clean and tighten all weld connections No 115 volts ac output at duplex recep tacle Remote 14 receptacle Reset circuit breaker CB1 see Section 3 7 No 24 volt...

Страница 29: ...OM 185 648 Page 25 Notes ...

Страница 30: ...OM 185 648 Page 26 SECTION 6 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram For Welding Power Source ...

Страница 31: ...OM 185 648 Page 27 SD 185 518 ...

Страница 32: ...available unless listed 801 930 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 34 35 36 37 38 39 40 41 42 43 4 44 45 46 48 49 50 46 51 52 53 57 58 36 60 59 61 62 63 64 4 PC1 PC2 3 65 4 5 6 7 8 30 10 47 54 55 56 66 Figure 7 1 Complete Assembly ...

Страница 33: ...ic shock 1 23 153 403 BUSHING snap in nyl 750 ID x 1 000mtg hole 2 24 025 248 STAND OFF insul 250 20 x 1 250 lg 4 25 W1 180 270 CONTACTOR def prp 40A 3P 24VAC 1 26 C1 2 188 446 CAPACITOR polyp film 5uf 900VAC 2 27 185 992 BUS BAR capacitor 2 28 CT1 181 271 TRANSFORMER current 500 turns 1 29 177 547 BUSHING snap in nyl CT MT 1 125mtg hole 1 30 T4 185 208 CHOKE common mode 1 31 PC2 187 243 CIRCUIT C...

Страница 34: ... BUS BAR output 1 179 276 BUSHING snap in nyl 1 000 x 1 375mtg hole 2 64 179 310 LABEL warning general precautionary 2 PLG4 131 056 HOUSING RECEPTACLE SOCKETS 1 RC10 166 679 HOUSING RECEPTACLE PINS SOCKETS 1 PLG2 115 092 HOUSING PLUG SOCKETS 1 PLG7 19 115 094 HOUSING PLUG SOCKETS 1 PLG9 11 115 091 HOUSING PLUG SOCKETS 1 PLG3 12 180 776 PLUG w leads voltage feedback 1 PLG5 15 16 175 026 PLUG w lead...

Страница 35: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories The...

Страница 36: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate 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 Informati...

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