OM-203 034R 2008−11 Processes Invision 456P: MIG (GMAW) Welding With Optional Equipment: Pulsed MIG (GMAW-P) XMT 456 CC/CV: Multiprocess Welding Description Invision 456P: XMT 456 CC/CV: Invision 456P And XMT 456 CC/CV R R (400 Volt Models) IEC File: MIG (GMAW) Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 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.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury. MOVING PARTS can cause injury. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
LES FILS DE SOUDAGE peuvent provoquer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher des organes mobiles tels que des ventilateurs.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
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SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 1.2 1.3 2 1 1.1 1.2 1.3 2.1 2.2 2.3 2 2.1 2.2 2.3 3 3.1 3 3.1 3.2 3.2 3.3 3.3 4 5 4.1 + 4 + + + 4.1 6 5 6 S-179 310 Electric shock from welding electrode or wiring can kill. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
1 2 3 1 2 3 4 5 6 4 V V > 60 s V 5 S-179 190-A 6 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 60 seconds after power is turned off before working on unit, OR Check input capacitor voltage, and be sure it is near 0 before touching any parts.
3-2.
SECTION 4 − INSTALLATION . This manual contains information on CC and CC/CV units. Differences between models are noted throughout this manual. 4-1. Specifications Input Power Rated Welding Output Amperage Range Voltage Range Maximum OpenCircuit Voltage DC Three Phase 450 A @ 38 Volts DC, 100% Duty Cycle; 550 A @ 42 Volts DC, 60% Duty Cycle 5 − 600 10 − 38 95 Amperes Input At Rated Load Output 50 Hz, Three-Phase 380 V 400 V KVA KW 33 31 21.6 19.4 4-2.
4-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. CV Modes CC Modes va_curve1 4/95 − SA-181 561 / SA-181 562 4-4. Dimensions And Weight Hole Layout Dimensions A A 14-21/64 in (363.9 mm) B 20-3/4 in (527.1 mm) C 23-27/64 in (594.9 mm) D 24-31/32 in (634.2 mm) E 12-3/8 in (314.3 mm) F 9/32 in (7.1 mm) Dia.
4-5. Selecting A Location Movement Tipping ! 2 Do not move or operate unit where it could tip. 3 OR 1 1 Location Lifting Forks Use lifting forks to move unit. 5 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. 18 in (460 mm) 4 4 Rating Label - Typical Use rating label to determine input power needs. 5 Line Disconnect Device Locate unit near correct input power supply.
4-7. Weld Output Terminals And Selecting Cable Sizes ! ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual.
4-8. Connecting Weld Output Cables 1 4 Do not place anything between weld cable terminal and copper bar. 2 Tools Needed: 3 3/4 in (19 mm) Incorrect Installation ! Turn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output terminal.
4-10. 115 Volts AC Duplex Receptacle 1 115 V 7 A AC Receptacle Power is shared between duplex receptacle and Remote 14 receptacle (see Section 4-9). 1 2 3 2 3 Circuit Breaker CB1 Circuit Breaker CB2 CB1 protects 115 volts ac portion of duplex receptacle and Remote 14 receptacle from overload. CB2 protects 24 volts ac portion of Remote 14 receptacle from overload. Press button to reset breaker. Ref. 801 524-A 4-11.
4-12. Connecting Input Power Input Filter Board L1 L2 =GND/PE ! Always connect grounding conductor first. L3 2 L1 L2 1 L3 Tools Needed: 5/16 in ssb2.4* 1/94 − 801 523-B / 801 946 ! Turn Off welding power source, and check voltage on input capacitors according to Section 6-3 before proceeding. Check input voltage available at site. Remove left side panel. OM-203 034 Page 20 1 Input And Grounding Conductors See Section 4-11.
SECTION 5 − OPERATION 5-1. Front Panel Controls For CV Only Models 2 1 4 3 5 ST-184 761 1 Power On/Off Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 Voltmeter (see Section 5-3) 5 Inductance Control 3 Ammeter (see Section 5-3) 4 Voltage Adjustment Control Inductance determines the “wetness” of the weld puddle. When set higher, “wetness” (puddle fluidity) increases. 5-2.
5-3. Meter Functions For CV Only Models . The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle V Meter Reading While Welding A V 24.5 250 Preset Volts Blank Actual Volts Actual Amps V A V A 24.5 MIG Pulsed MIG A PPP PPP 24.5 250 Pulse Display Pulse Display Actual Volts Actual Amps 5-4. Front Panel Controls For CC/CV Models 2 1 7 6 3 4 5 196 445 1 Power Switch .
5-5. Meter Functions For CC/CV Models . The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle V Panel Control (GTAW) Lift-Arc Trigger Hold TIG (GTAW) 80.0 Pulsed MIG (GMAW-P) Voltage-Sensing Wirefeeder Remote Control SMAW Panel Control SMAW 85 Actual Volts (OCV) Preset Amps V A 85 Blank Preset Amps V A 85 TIG (GTAW) MIG (GMAW) A Blank Preset Amps V A 24.
5-6. Mode Switch Settings For CC/CV Models . The SMAW modes provide the Adaptive Hot Start™ feature, which automatically increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start.
5-7. Lift-Arc TIG Procedure For CC/CV Models With Mode switch in the Lift-Arc TIG position, start an arc as follows: 1 “Touch” 1−2 Seconds 2 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted. Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece.
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! . Maintain more often Disconnect power before maintaining. during severe conditions. 3 Months Repair Or Replace Cracked Cables Replace Damaged Or Unreadable Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Terminals 6 Months Blow Out Inside 6-2. Blowing Out Inside Of Unit ! Do not remove case when blowing out inside of unit.
6-3. Removing Case and Measuring Input Capacitor Voltage ! Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit. 1 1 Turn Off welding power source, and disconnect input power. 1 Outside Handle Screws To loosen top, remove two outside handle screws from both handles and all side bolts.
6-4. Voltmeter/Ammeter Help Displays 1 2 3 4 5 6 7 8 V A HE.L P−0 V A HE.L P−1 V A HE.L P−2 V A HE.L P−3 V A HE.L P−4 V A HE.L P−5 V A HE.L P−6 V A HE.L P−7 V A HE.L P−8 . All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 1 2 10 OM-203 034 Page 28 V A HE.L P−9 Help 1 Display Indicates a malfunction in the primary power circuit.
6-5. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 4-12). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (see Section 4-12). No weld output; meter display On. Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 4-2). Erratic or improper weld output.
SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1.
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Figure 7-2.
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SECTION 8 − PARTS LIST . Hardware is 25 common and not available unless listed. 26 27 22 68 21 28 24 29 20 19 23 30 18 4 31 17 PC2 16 10 11 12 32 15 33 14 35 PC1 13 9 34 36 39 40 41 42 37 8 43 38 7 6 36 4 5 3 60 4 61 67 62 44 57 45 59 46 2 63 47 56 58 55 48 1 65 64 66 54 49 53 52 51 Figure 8-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Complete Assembly . . . 1 . . . . . . . . . . . . . . . . 187 234 . . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . 195 585 . . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . +190 373 . . . Panel, Side Rh . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Complete Assembly (Continued) . . . 48 . . . . . . . . . . . . . . . . 180 732 . . . Boot, Neg Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 . . . . . . . . . . . . . . . . 179 848 . . . Boot, Pos Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . . . 179 898 . . . Panel, Front . . . . . . . . . . . . . . .
229895 Notes MATERIAL THICKNESS GAUGE
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Effective January 1, 2008 (Equipment with a serial number preface of LJ or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.