Miller Electric MT-24VF-12-1 Owner`s manual

OM-187 476D
March 2003
Effective with serial number: 195 503
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Description
Arc Welding Power Source
Blu-Pak 35/45
Visit our website at
www.MillerWelds.com
OWNER’S MANUAL
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.
Today, the people that build and sell Miller products continue 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 operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of
welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS–READ BEFORE USING . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . .
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Typical MIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Remote 14 Receptacle RC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 - ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 - PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
3
3
4
6
6
6
6
6
7
7
7
8
8
8
9
9
10
10
10
11
12
Declaration of Conformity
Manufacturer’s Name:
MILLER Europe S.r.l.
Manufacturer’s Address:
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Declares that this product:
Blu-Pak 35/45
Conforms to the following Directives and Standards:
Directives
Electromagnetic Compatibility Directives: 89/336/EEC
Low Voltage: 73/23/EEC
Machinery Directives: 89/392/EEC
And their amendments 91/368/EEC, 93/31/EEC, 93/44/EEC, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995
Safety Requirements for Arc Welding Equipment Part 1: EN 60974-1: 1989
European Contact:
Telephone:
Fax:
dec_con1_italy_11/02
Ing. Danilo Fedolfi, Managing Director
ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
39(0)298290-1
39(0)298290-203
SECTION 1 – SAFETY PRECAUTIONS–READ BEFORE USING
som_woPSS_7/02
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y 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. Read and follow all Safety Standards.
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.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
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.
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
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 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.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
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 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 and ground 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 conductor 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.
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 exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-187 476 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
WELDING can cause fire or
explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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 and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off 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 slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-187 476 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect
pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols for Installation, Operation, and Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
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.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
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 is
electromagnetically compatible.
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.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields 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 side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-187 476 Page 3
SECTION 2 – DEFINITIONS
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1 Electric shock can kill.
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
1.2 Protect yourself from electric shock
by insulating yourself from work and
ground.
1.3 Disconnect input plug or power
before working on machine.
2 Breathing welding fumes can be
hazardous to your health.
OM-187 476 Page 4
2.1 Keep your head out of the fumes.
2.2 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 injure
skin.
4.1 Wear hat and safety glasses. Use
ear protection and button shirt collar.
Use welding helmet with correct
shade of filter. Wear complete body
protection.
5
Become trained and read the
instructions before working on the
machine or welding.
6
Do not remove or paint over (cover)
the label.
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.
Read the Owner’s Manual before
working on this machine.
1
Consult rating label for input
power requirements, and
check power available at the
job site – they must match.
Read Owner’s Manual and
inside labels for connection
points and procedures.
Move jumper links as shown
on inside label to match
voltage at job site.
Having a loop of extra length,
connect grounding conductor
first.
Connect line input conductors
as shown on inside label –
double-check all connections,
jumper link positions, and
input voltage before applying
power.
2
3
4
5
1
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Moving parts, such as fans,
can cut fingers and hands and
cause injury. Keep away from
moving parts.
2
2
S-176 106
1
1
1
2
3
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling unit can cause injury.
Do not move or operate unit
where it could tip.
Cylinders can expolde if
damaged. Protect
compressed gas cylinders
from excessive heat,
mechanical shock, slag, open
flames, sparks, and arcs.
3
OM-187 476 Page 5
SECTION 3 – INTRODUCTION
3-1. Included with Your Unit
1
1
2
3
4
Power Source
Power Cord (4m)
Work Cable and Clamp (4m)
Running Gear
2
3
4
3-2. Specifications
Rated Output
at 45% Duty
Cycle
Welding
Range
Max. OVC
Input Rating
KVA
Dimensions
Net Weight
Blu-Pak 35
350 A 32 V
16-32
38
230-31A
400–18A
11.8 KVA
Length:
1040mm
Height: 760mm
Width: 435mm
146 kg
Blu-Pak 45
450 A 37 V
14-37
47
230-46A
400-27A
17.7 KVA
Length:
1040mm
Height: 760mm
Width: 435mm
156 kg
3-3. Duty Cycle Chart
Duty cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
WELDING AMPERES
800
700
Blu-Pak 35: 45% Duty Cycle at 32V, 350A
600
500
Blu-Pak 45: 45% Duty Cycle at 37V, 450A
400
450
300
200
20
350
4.5 Minutes
Welding
25 30 35 40 50 60 708090100
% DUTY CYCLE
3-4. Volt-Ampere Curves
Blu-Pak 35
OM-187 476 Page 6
Blu-Pak 45
5.5 Minutes
Resting
SECTION 4 – INSTALLATION
4-1. Selecting a Location
Position unit so air can circulate.
500 mm
500 mm
500 mm
4-2. Typical MIG Connections
6
1
Power source
2
Work clamp (connect to receptacle as shown)
3
Water cooler for torch
4
Cylinder (chain to running
gear)
5
Cylinder valve
5
7
Open valve slightly so gas flow
blows dirt from valve. Close valve.
6
Regulator/Flow gauge
Install so face is vertical
7
Flow adjust
8
Gas supply line
9
Wire feeder
8
4
3
10 MIG torch
9
1
10
2
OM-187 476 Page 7
4-3. Electrical Service Guide
Blu-Pak 35
Input Voltage
Blu-Pak 45
230
400
230
400
Input amperes at rated output
36A
21A
52A
30A
Fuse or circuit breaker rating (max. rec)
36A
21A
52A
30A
Input conductor size*
6 mm2
6 mm2
6 mm2
6 mm2
Grounding conductor size**
6 mm2
6 mm2
6 mm2
6 mm2
* Power cord supplied with the unit is sized for 230V operation.
** Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations.
4-4. Connecting Input Power
ST-161 454-A
GND/PE
Y Have only qualified persons
make this installation.
Y Special installation may be
required where gasoline or
volatile liquids are present –
consult national or local regulations.
GND/PE
Connect first.
L1
L2
L3
Tools Needed:
4-5. Remote 14 Receptacle RC1
Socket
OUTPUT
(CONTACTOR)
24 VOLTS AC
115 VOLTS AC
GND
OM-187 476 Page 8
OUTPUT
Information
A
24 volts ac.
B
Contact closure to A completes 24 volts ac contactor control circuit.
I
115 volts AC, protected by fuse.
K
Chassis common.
G
Circuit common for 24 and 115 volts ac circuits.
SECTION 5 – OPERATION
5-1. Controls
Ref. ST-155 790-F
1
Power Switch
2
5
6
The power switch is a selector knob
which permits selection of operation
on either of the two available ranges
(I and II) and the center position is off.
2
Indicator Lamp
This lights up when the power switch
is placed in the ON position.
3
1
Protection Fuse
Fuse F protects the control circuit.
Should it become necesary to replace any fuse in the welding power
source, be sure to substitute with one
of the same size and rating.
4
High Temperature Shutdown
Light
3
4
7
This lights up when unit overheats
and shuts down.
5
Use this control to adjust weld
voltage 10 position switch. 20
weld setting, 10 high range (I),
10 low range (II).
6
Voltage/Amperage Meter.
8
Use toggle switch to select voltage or
amperage.
7
Low Inductance Negative
Output Terminal
Connect work lead here for most
“short-arc” applications.
8
Front Panel
High Inductance Negative
Terminal
Connect work lead here for stainless
steel and spray arc conditions.
9
9
10
11
115 a.c. Receptacle
Located on the rear panel is a receptacle which provides power to the gas
heater, when welding with CO2
shielding gas and for the cooling system.
10 Wire Feeder Power Cable
Receptacle
Located on the rear panel is a receptacle used to supply operating power
to the wire feed unit.
11 Positive Out Terminal
115 VAC
Back Panel
OM-187 476 Page 9
SECTION 6 – MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
Y Disconnect power before maintaining.
. Maintain more often during severe conditions.
3 Months
Replace unreadable labels.
Clean and tighten weld terminals.
Repair or replace cracked weld
cable.
Repair or replace cracked gas
hose.
Replace o-ring in Electrode/Gas
Output receptacle if cracked.
6 Months
Blow out or vacuum inside.
OR
6-2. Troubleshooting
Trouble
Remedy
No weld output; fan does not run.
Place line disconnect switch in On position (see Section 4-4).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-4).
Check for proper input power connections (see Section 4-4).
No weld output; fan on.
Check and replace if necessary (see Section 5-1)
Tighten wire feeder connection to Remote 14 receptacle.
Unit overheated. Allow unit to cool (see Section 3-3).
Fan not operating; weld output
available.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
OM-187 476 Page 10
3
F
1
22
B
CR
20
AT
GND
5
IN RECT.TP
R
S
T
13
OL
FM
W
W
2
G
w
6
RC1
23
R
21
A
RC2
230V
S3
14
W
PL
20
10
11
W
C1
S2
RL 1
1 2 3 4 5 6 7 8 910 1112
SL 2
C2
4
TL 3
K
24V
RC3
9
C3
T3
L
115
115V
400V
Y
Z
X
PRI.
POSIZIONI
7
U 8
S3
2 1 2 1 2 1
B
MT
B
V 19
W
B
RL 1
S2
SL 2
R1
TL 3
1 2 3 4 5 6 7 8 9 10 1112
B
B
B
SEC.
SR1
RC1
Vc
28
26
25
SHUNT
DIGITAL A-V
X
X
1X
2 X
X
X
X
3 X
X
X
4 X
X
5
X
X
X
X
6
X
X
X
7
X
X
8
X
X
X
9
X
X
X
X
10
X
X
Z
W
+
27
24
1 2
3 4
5 6
29
31
30
12
24 Vac
SECTION 7 - ELECTRICAL DIAGRAM
7-1. Blu-Pak 35/45
cod.956.142.300/956.142.301
OM-187 476 Page 11
SECTION 8 - PARTS LIST
8-1. Main Assembly
1
45
2
10
35
34
36
40
3
37
33
39
38
32
4
5
31
30
6
29
7
41
43
8
28
9
27
26
25
10
23
42
51
20
52
19
44
24
12
15
11
50
13
49
14
48
16
47
46
OM-187 476 Page 12
17
18
21
22
Dia
Item
Ref.
Code
1
116121119
2
156002023
3
PL
056072054
4
058020044
4
056020042
5
000046432
6
F
056092039
7
OL
056072062
8
056020043
8
056020031
9
116118150
10
50mmq 056076152
10
70mmq 056076169
11
056054065
12
116085123
13
116005081
14 TP.NC.110_ 056159008
15
SR1
056050058
15
SR1
056050017
16
SHUNT 056059257
16
SHUNT 056059262
17 MT 230/400V 028021447
17 MT 230/400V 028021448
18
PRI. SEC 027015542
230/400V
18
PRI. SEC 027015541
230/400V
19
156031040
20
Z
028038040
20
Z
028038041
21
556070011
22
756069012
23
156006030
24
W
057079033
Aux. Contact 056070038
24
W
057079034
Aux. Contact 056070038
Qty.
Dwg
35 45
XH.0.0.3
1
1
VS.0.0.15 2
2
EG.1.0.4
1
1
VS.0.0.17 1
VT.0.0.5
1
OL.0.0.14
EZ.4.0.5
1
1
QF.0.0.10 1
1
VS.0.0.16 1
MN.3.0.3
1
VS.0.0.2
1
1
DD.0.0.7
3
DI.11.0.2
3
VS.0.014 2
2
VS.0.0.8
1
1
XH.0.0.11 1
1
QF.0.0.7
1
1
HC.0.0.2
1
AS.0.0.1
1
UV.3.0.1
1
VT.0.0.1
1
VS.8
1
VT.6
1
VS.1.1
3
VT.1.1
VT.0.0.7
VS.2
VT.2
HD.0.02
BO.0.0.6
XH.0.0.6
VS.0.31
VT.0.13
3
1
1
4
1
1
1
1
1
4
1
1
1
Dia
Item
Ref.
Code
25
056054064
26
156009067
27
156087017
28
057029005
29
117029078
30
057014030
31
356078032
32
116118151
33
000173283
34
RC2
000604176
35
RC1
056076170
36 Destra/Right 116122277
36 Sinstra/Left 116122278
37
000124274
38
FM
000116190
(230V, 50/60 Hz)
39
S2
056067196
39
S2
056067205
40
S3
056067203
40
S3
056067204
41
A-V
027095012
41
A-V
027095013
42
AT
058021042
43
656089005
R
056059189
C1-C2-C3 057024004
44
116122280
45
CR
000006393
46
47
156085088
48
156085087
49
156031032
50
156031034
51
157029012
52
156031033
Qty.
35 45
2
2
6
6
2
2
VS.0.3
1
1
VS.0.2
1
1
ML.0.3
1
1
PZ.0.0.8
1
1
VS.0.0.3
1
1
QB.0.0.13 1
1
EF.6.0.3
1
1
FS.1.0.3
1
1
VS.0.0.5
1
1
VS.0.0.6
1
1
QA.0.4.3
1
1
QB.0.12
1
1
Dwg
VS.0.013
UV.0.011
VT.0.0.3
VS.0.0.10
VT.0.0.2
VS.5.1
VT.4.1
MI.5
EZ.5.0.1
DH.6.0.4
PG.0.7
VS.0.0.11
QA.0.0.10
XH.0.0.10
XH.0.0.8
XH.0.0.7
XH.0.0.12
XH.0.0.14
XH.0.3
XH.0.0.13
1
1
1
1
1
1
1
1
1
1
1
4
2
2
1
1
1
1
1
1
1
1
1
1
1
4
2
2
1
1
1
1
OM-187 476 Page 13
Notes
Effective January 1, 2002
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Europe S.r.l., Milan Italy, warrants to its original
retail purchaser that new Miller equipment sold after the
effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a European
distributor or eighteen months after the equipment is sent to
an International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
4.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators except Panther
(NOTE: Engines are warranted separately by the
engine manufacturer.)
2 year – Parts and Labor (Panther only)
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 year – Parts and Labor unless specified
* DS-2 Feeder
* Motor Driven Guns (w/exception of Spoolguns)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* IHPS Power Sources
* Water Coolant Systems
* Flowgaruge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True Blue
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
5
6 Months — Batteries
6.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction heating coils and blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
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. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
milan_warr 10/02
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
Country
Zip/Postal Code
Miller Europe
Italy
Phone: 39 (0) 2982901
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
Phone: 920-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
PRINTED IN USA
 2003 Miller Electric Mfg. Co. 1/03