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OM-287504 Page 1

SECTION 1 

 SAFETY PRECAUTIONS - READ BEFORE USING

som 2020

02

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

these 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 Principal Safety Standards listed in Section 1-5.

Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this equipment. A qualified person is defined as one

who, by possession of a recognized degree, certificate, or

professional standing, or who by extensive knowledge, train-

ing and experience, has successfully demonstrated the

ability to solve or resolve problems relating to the subject

matter, the work, or the project and has received safety train-

ing to recognize and avoid the hazards involved.

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.

Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

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

Insulate yourself from work and ground using dry insulating mats

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

or ground.

Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

Use AC output ONLY if required for the welding process.

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

unit.

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!

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).

Properly install, ground, and operate this equipment according to

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

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.

When making input connections, attach proper grounding conduc-

tor first 

 double-check connections.

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

and sparks.

Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare

wiring can kill.

Turn off all equipment when not in use.

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

Do not drape cables over your body.

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

with a separate cable.

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

or another electrode from a different machine.

Do not touch electrode holders connected to two welding ma-

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

present.

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

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

or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal. Disconnect cable for process not in

use.

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.

Turn off unit, disconnect input power, and discharge input capaci-

tors according to instructions in Manual before touching any parts.

HOT PARTS can burn.

Do not touch hot parts bare handed.

Allow cooling period before working on

equipment.

To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

Содержание MigMatic S400i

Страница 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...

Страница 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...

Страница 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...

Страница 4: ......

Страница 5: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

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

Страница 41: ...Notes...

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

Страница 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...

Страница 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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