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OM-257 798 Page 1

SECTION 1 

 SAFETY PRECAUTIONS - READ BEFORE USING

som 2013

09

7

Protect yourself and others from injury —

 

read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! 

 Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.
Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE

 

 Indicates statements not related to personal injury.

.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks

or  severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll housing,

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D

Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D

Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on

unit.

D

Additional safety precautions are required when 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 such

as sitting, 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

semiautomatic DC 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 work alone!

D

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D

Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

D

Always verify the supply ground 

 check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box 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

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D

Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare

wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or repaired cables.

D

Do not drape cables over your body.

D

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

D

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D

Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in

use.

D

Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of input power.

D

Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can burn.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on equip-

ment.

D

To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

Содержание Continuum 350

Страница 1: ...And Continuum 500 Processes Description Arc Welding Power Source Visit our website at www MillerWelds com Air Carbon Arc CAC A Cutting and Gouging File Advanced Manufacturing Systems MIG GMAW Welding...

Страница 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...

Страница 3: ...FICATIONS 14 4 1 Serial Number And Rating Label Location 14 4 2 350 Model Specifications 14 4 3 500 Model Specifications 14 4 4 Dimensions And Weight 14 4 5 Environmental Specifications 15 4 6 Static...

Страница 4: ...Management Screen 35 8 5 Data Management Screen 36 8 6 Help Screen 36 SECTION 9 MAINTENANCE TROUBLESHOOTING 37 9 1 Routine Maintenance 37 9 2 Blowing Out Inside Of Unit 37 9 3 Error Code Troubleshoot...

Страница 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...

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

Страница 7: ...NG PARTS 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...

Страница 8: ...NFPA 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...

Страница 9: ...UNIQUE MENT si le proc d de soudage le demande D Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D aut...

Страница 10: ...nts et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc D Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste laine...

Страница 11: ...ci s en bon tat D Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne D Le couvercle du d...

Страница 12: ...es de rechange recommand es par le constructeur D Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR...

Страница 13: ...l 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 Par...

Страница 14: ...ock 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 ventilatio...

Страница 15: ...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...

Страница 16: ...Voltage U2 Conventional Load Voltage X Duty Cycle Hz Hertz IP Degree Of Protection I2 Rated Welding Current Percent Cold Jog Inch Away From Workpiece S Suitable for Some Hazardous Locations Three Pha...

Страница 17: ...OM 257 798 Page 13 Notes...

Страница 18: ...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...

Страница 19: ...5 Environmental Specifications A IP Rating IP Rating 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 sh...

Страница 20: ...ol Reduce amperage 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 duty...

Страница 21: ...lift eye is inserted through slot in feeder base 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...

Страница 22: ...0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 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 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60...

Страница 23: ...ut tab are clean 1 Negative Tab 2 Positive Tab 3 Correct Weld Cable Connection For Single Feeder 4 Correct Weld Cable Connection For 2 0 And Larger Double Cables 5 Incorrect Weld Cable Connection 6 We...

Страница 24: ...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...

Страница 25: ...e wirefeed motor from overload If CB1 opens the wirefeeder does not work Press button to reset breaker If breaker continues to open contact a Factory Authorized Service Agent Ref 259 119 A 2 1 Ref 269...

Страница 26: ...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...

Страница 27: ...OM 257 798 Page 23 Notes...

Страница 28: ...24 5 9 Connecting 3 Phase Input Power input5 2013 04 259 121 B Tools Needed Top 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 V 6...

Страница 29: ...e Welding Power Source Input Power Connections 2 Strain Relief Customer Supplied Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief Tighten...

Страница 30: ...provide satisfactory performance 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 Wo...

Страница 31: ...utomatically becomes enabled for all semi automatic processes The work sense lead connects to the welding power source 4 pin connector located above the positive output terminal This work sense lead a...

Страница 32: ...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...

Страница 33: ...ial 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 re...

Страница 34: ...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...

Страница 35: ...rk 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 zo...

Страница 36: ...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 4 Drive motor tachom...

Страница 37: ...Power LED illuminates when unit is energized 3 Output On LED Output LED illuminates when weld output is energized 4 Over Temperature LED Over Temperature LED illuminates if unit overheats Stop weldin...

Страница 38: ...n asset number serial num ber and display language 3 Power Source Information Displays power source information Edit but ton allows these parameters to be changed 4 Active Program Displays the program...

Страница 39: ...changed 7 Status Displays the status of Insight software Edit button allows that status to be changed 1 2 5 3 4 7 6 8 4 Arc Management Screen 1 Active Program Displays the program number process wire...

Страница 40: ...tem View button displays a list of previous errors and the time at which they occurred 3 System Log Displays the last entry into the system log View button displays a list of the entries made to the...

Страница 41: ...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 Con...

Страница 42: ...Error ERR GND CRNT ERROR Weld current detected in earth ground Check and repair feeder weld connections Earth Ground Current Error ERR WIR STUK ERROR Wire stick to workpiece at the end of the weld Br...

Страница 43: ...ower THERM3 Overtemp Error ERR THERM 1 ERROR Thermistor 1 shorted Cycle power on the power source THERM1 Shorted Error ERR THERM 2 ERROR Thermistor 2 shorted Cycle power on the power source THERM2 Sho...

Страница 44: ...NOWN ERROR An unknown error has occurred Update software Unknown Error 9 4 Troubleshooting Trouble Remedy No weld output completely inoperative Place line disconnect in On position see Section 5 9 Che...

Страница 45: ...OM 257 798 Page 41 Notes...

Страница 46: ...OM 257 798 Page 42 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For Contiuum 350 Model Page 1 of 2...

Страница 47: ...OM 257 798 Page 43 264 238 B...

Страница 48: ...OM 257 798 Page 44 Figure 10 2 Circuit Diagram For Continuum 350 Model Page 2 of 2...

Страница 49: ...OM 257 798 Page 45 264 238 B...

Страница 50: ...OM 257 798 Page 46 Figure 10 3 Circuit Diagram For Contiuum 500 Model Page 1 of 2...

Страница 51: ...OM 257 798 Page 47 265 841 B...

Страница 52: ...OM 257 798 Page 48 Figure 10 4 Circuit Diagram For Continuum 500 Model Page 2 of 2...

Страница 53: ...OM 257 798 Page 49 265 841 B...

Страница 54: ...Page 50 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 7 3 8 4 10 1 5 11 13 14 15 16 2 6 12 269 779 A 9 17 17 18 Figure 11 1 Main...

Страница 55: ...1 1 9 269472 Gasket Sealing 17 000L x 250w x 063t 1 1 10 Figure 11 5 Front Panel Assy Lower Continuum 1 1 11 Figure 11 6 Penthouse Assy 1 1 12 Figure 11 2 Windtunnel Rh W Cmpnts 1 1 13 Figure 11 3 Win...

Страница 56: ...ulator Screw 4 4 9 025248 Stand 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 Curr...

Страница 57: ...Boost 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...

Страница 58: ...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...

Страница 59: ...r 890 Od 1 12 178548 Terminal Connector Friction 1 13 186228 O ring 0 739 Id X 0 070 H 1 14 185718 O ring 0 989 Id X 0 070 H 1 15 252830 Terminal Pwr Output Front Bolted Rear Int Thread 1 16 185714 Wa...

Страница 60: ...30 W 200 Ohm Faston Te 1 6 265261 Lift Eye Formed 2 266393 Label Warning Input Connections Electric Shock 1 7 266232 Lift Eye 1 8 256975 Seal Lift Eye 1 9 PC19 263175 Circuit Card Assy Wega SBC 1 10...

Страница 61: ...1 5mmod 1 310 1mmt Intern 1 9 185717 Nut M20 1 5 1 00hex 19h Brs Locking 2 10 257290 Panel Rear Blank 1 11 263536 Rail Din 35mm X 7 5mm X 1 969in 1 12 267439 Bracket Rear Weld Conn 1 13 179848 Boot Po...

Страница 62: ...OM 257 798 Page 58 Notes...

Страница 63: ...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...

Страница 64: ...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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