Miller | KH504356 | Owner Manual | Miller PHOENIX 456 CC/CV (575 VOLT) User manual

Miller PHOENIX 456 CC/CV (575 VOLT) User manual
N
QM-188 989A
November 1997
Eff. w/Serial Number KH504356
N
N
Processes
Invision 456P:
The Thwer fBkte.
N
N
~
MIG
(GMAW) and Pulsed
(GMAW-P) Welding
Flux Cored
(FCAW) Welding
Phoenix 456 CC/CV:
Multiprocess Welding
N
N
Description
lnvision 456P:
N
N
~NN
Phoenix 456
N
N
CC/CV:
N
N
Invisionfi456P and
Phoenixfi456 CC/CV
N
(575
NN
N
Volt
Models)
N
N~
N
N
N
N
N
ND
~
OWNERS
:VWww~MUterWcid8~COfl~.Y
N
MIG
MANUAL
From Miller to You
Thank you and
you
can
get the
you dont
Thats
congratulations on choosing Miller. Now
job done and get it done right. We know
have time to do it any other way.
why
when Niels Miller first started
building arc
products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
welders in
1929, he made
sure
his
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
Today,
the
This Owners
Miller
help
Manual is
designed
to
help
you get the most out of your
Please take time to read the
products.
yourself against potential
you protect
Safety precautions. They
hazards
on
will
the worksite. Weve
made installation and
operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
iIk~iIllhIIJP
IREGISTEREDI
IQUALITY SYSTEM
some reason
the unit needs
______________
repair,
theres
a
section that will
Troubleshooting
help you
what
the
is.
The
out
figure
problem
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 is the tirat welding equip
mentmanufacturerlntheU.S.A.to
be registered to the ISO oooi
quality System Standard.
W~1~ftflfl~
L~
Working as hard as you do~ every
power source from Miller is
backed by the most hassle-free
warranty in the business.
Miller Electric manufactures
of welders and
welding
For information
on
a
full line
related
other
equipment.
quality Miller
your local Miller distributor
to receive the latest full line catalog or
products,
contact
individual
catalog
sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
f//A Miller
Thwer~fBhte~
Call
1 -800-4-A-MILLER
for your local
TABLE OF CONTENTS
SECTION 1
Miller disiributor.
SECTION 1
1-1.
1-2.
1-3.
hands in 24 hours.
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.
1
and Maintenance
3
3
4
CONSIGNES DE SECURITE
-
Signification des symboles
Dangers relatifs au soudage a larc
Dangers supplØmentaires en relation
LIRE AVANT UTILISATION
5
5
5
avec
Iinstallation,
le fonctionnement
7
1-4.
Principales
normes
1-5.
Information
sur
les
de sØcuritÆ
8
champs electromagnetiques
SECTION 2- INSTALLATION
8
9
2-2.
Specifications
Duty Cycle and Overheating
2-3.
Volt-Ampere Curves
10
2-4.
Dimensions And
11
2-1.
9
9
12
2-8.
Weight
Selecting a Location
Weld Output Terminals and Selecting Cable Sizes
Remote 14 Receptacle Information
115 Volts AC Duplex Receptacle And Circuit Breakers
2-9.
Electrical Service Guide
13
2-10.
Connecting Input
2-5.
2-6.
Miller offers a Technical
Manual which provides
more detailed service and
parts in formation for your
unit. To obtain a Technical
ManuaI~ contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
1
1
et Ia maintenance
Support
Need fast
READ BEFORE USING
EMF Information
gives
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
-
1-5.
1-3.
you
SAFETY PRECAUTIONS
1-4.
1-2.
Your distributor
-
Symbol Usage
Arc Welding Hazards
Additional Symbols for Installation, Operation,
Principal Safety Standards
1-1.
2-7.
11
12
13
14
Power
SECTION 3-OPERATION
15
3-1.
Front Panel Controls For Invision 456P
15
3-2.
Mode and
15
as SMAW, GTAW,
GMAW, and GMAW-P
3-3.
Meter Functions For Invision 456P
3-4.
Front Panel Controls For Phoenix 456 CC/CV
16
practical information on
welding, process applica
tions, and Miiler products,
3-5.
Meter Functions For Phoenix 456
17
3-6.
Mode Switch
3-7.
Lift-Arc TIG Procedure For Phoenix 456 CC/CV
such
For
visit
Voltage Control
Settings
For Invision 456P
CC/CV
For Phoenix 456 CC/CV
SECTION 4- MAINTENANCE AND TROUBLESHOOTING
www.MlllerWelds.com
4-1.
Routine Maintenance
4-2.
Blowing Out Inside of Unit
Removing Case and Measuring Input Capacitor Voltage
Voltmeter/Ammeter Help Displays
Troubleshooting
4-3.
4-4.
4-5.
The
following terms are
interchangeably
throughout this manual:
used
=
18
GTAW
SMAW
=
OM-186 989
16
18
19
20
21
22
SECTION 5- ELECTRICAL DIAGRAF~t
24
SECTION 6- PARTS LIST
26
WAR RANTY
Stick
17
website at
our
TIG
16
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
som
I
Cti~ik
iii
.~o1
I
A
~
~
Out!
Watch
Warning!
hazards with this procedure! The
shown in the adjoining symbols.
Marks
a
~.
~.
~
Means
4~
T~1
~sa~,e
~,,y
~
not
.*...
There
are
possible
possible hazards are
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.
special safety message.
~ Means Note~
safety related.
~
Hazard
...
__________N
~
A
The
symbols
are used throughout thIs manual
Identify possible hazards. When you
shown below
to call attention to and
symbol, watch out, and foliowthe related Instructions
safety Information given below Is
only a summary of the more complete safety Information
found In the Safety Standards listed In Section 1-4. Read and
follow all Safety Standards.
see
the
to avoid the hazard. The
A
A
Only qualified persons should Install, operate, maintain,
repair this unit.
During operation, keep everybody, especially children,
and
away.
If earth
with
grounding of the workpiece
separate cable
Use
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
hole-free
dry,
are
is
required, ground it directly
clamp or work cable.
work
in contact with the work,
ground,
different machine.
a
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
parts
Wear
a
Keep
all
safety
harness if
and
panels
working
covers
worktable
as near
above floor level.
securely
Clamp work cable with good
in
place.
metal-to-metal contact to
the weld
as
workpiece
practical.
clamp when not connected to workpiece to prevent
object.
Do not connect
~
use
contact with any metal
live
Touching
do not
another electrode from
Insulate work
cton.
\
Wear
a
Do not touch electrode if you
or
or
=t~L~~
_nd_5/97
single
weld
more
than
one
electrode
or
work cable to any
output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off
inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
parts.
insulating gloves
and
body protection.
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
Insulate
Do not
use
there is
a
AC output in damp areas, if movement is confined,
of falling.
output is required,
if
Keep your
required for the welding process.
use
remote
output control if present
on
unit.
Disconnect
to
If
input power or stop engine before installing or
equipment. Lockout/tagout input power according
OSHA29 CFR 1910.147 (see Safety Standards).
Properly
Owners
this
install and
ground
this
equipment according
to
its
Manual and national, state, and local codes.
head out of the fumes. Do not breathe the fumes.
inside, ventilate the
remove
servicing
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Welding produces
I
danger
Use AC output ONLY if
If AC
or
I
I
If ventilation is poor,
Read
the
Material
manufacturers
area
and/or
use
exhaust at the
arc
to
fumes and gases.
welding
use an
Safety
approved air-supplied respirator.
Data
Sheets
(MSDS5)
instructions for metals, consumables,
and
the
coatings,
cleaners, and degreasers.
Work in
a
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.
wearing
an
When
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.
making input connections,
conductor first
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Turn off all
equipment
Do not
use
worn,
Do not
drape
when not in
only if it is well ventilated, or while
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.
Do not weld
cadmium
use.
confined space
on
weld area, the
damaged, undersized,
cables
over
your
body.
or
poorly spliced
cables.
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
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-186 989
Page
1
~urneyesi
ican
...
.
.~....
Shutoff shielding gas supply when not in
Always ventilate confined spaces or
approved air-supplied respirator.
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.
awelding helmet fitted with a proper shade of filterto protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
use.
use
Wear
Urns~
with side shields under your
approved safety glasses
Wear
helmet.
Use
Do not touch hot
Allow
protective screens or barriers to protect others from flash and
others not to watch the
parts
bare handed.
before
cooling period
working
on
or
gun
torch.
glare;
warn
Wear
protective clothing made from durable,
(leather and wool) and foot protection.
arc.
flame-resistant
material
. ~
,~
Pacemaker
closed containers, such as tanks,
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.
Protect
Welding
on
drums,
pipes,
yourself
or
and others from
Do not weld where
flying sparks
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
cover
~
(10.7 m)
NO! SE:ca
:
fire,
and
Be
that
welding
aware
can cause
fire
Do not weld
on
on
keep
a
fire
on a
of the
welding arc.
approved covers.
closed containers such
Connect work cable to the work
unknown
Do not
as
Noise from
prevent welding
as
processes
or
Wear
or
approved
ear
protection if
noise level is
protective garments
welding area as
traveling long, possibly
hazards.
~t
Protect
cut off
welding
wire at
compressed gas cylinders from excessive heat,
shocks, slag, open flames, sparks, and arcs.
mechanical
Install
such
as
a
leather
~
gloves, heavy
cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
f ~
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.
cylinders in an upright position by securing to
or cylinder rack to prevent falling or tipping.
lighter
Never
drape
Never allow
or
matches,
ssaTc~r..:r. ~ ..?.A.. ..?.
JNGMETALcanInJureeyes~
Never weld
a
a
welding torch
over a
welding electrode
on a
or
stationary
gas
other electrical circuits.
cylinder.
to touch any
pressurized cylinder
cylinder.
explosion will
result.
Use
only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
Turn face away from valve outlet when
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
a
support
Keep cylinders away from any welding
shirt, cuffless trousers, high shoes, and
2
can
Shielding
(see
pipes.
Remove stick electrode from holder
tip when not in use.
Page
equipment
high.
pipes,
to AWS F4.1
contact
OM-186 989
or
If
close to the
current from
welder to thaw frozen
Wear oil-free
some
damage hearing.
partition
or
tanks, drums,
paths and causing electric shock and fire
use
aniage :eÆ
the hidden side.
they are properly prepared according
Safety Standards).
to
spot
extinguisher nearby.
ceiling, floor, bulkhead,
unless
practical
or
and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for
keep away.
going near arc welding, gouging,
welding operations.
strike flammable material.
them with
wearers
Wearers should consult their doctor before
opening cylinder
and
and
valve.
Keep protective cap in place over valve except when cylinder is
use or
connected for
Read and follow instructions
associated
Standards.
in
use.
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
~
1-3m
Maintenance
~Additibn~FSymbo1ifor InMaflatlon, Operat1on~ md ~
~
6
~
Do not install
S
~
~
place unit
or
on, over, or
Keep away
near
combustible surfaces.
Do not install unit
S
Do not overload
is
properly sized, rated,
and
near
be
building wiring
Keep
protected
closed and
flammables.
sure
power
equipment
of
moving parts
securely
in
such
as
covers, and
fans.
guards
place.
supply system
to handle this unit.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use
from
doors, panels,
all
adequate
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
capacity to lift and
support unit.
Have
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
only qualified persons familiar with
equipment perform this installation.
electronic
unit.
The
responsible for having a qualified electrician
problem resulting from the
is
user
correct any interference
installation.
promptly
~.ause
Allow
cooling period;
Reduce current
starting
to weld
Do not block
or
or
follow rated
reduce
duty cycle.
duty cycle before
If notified
by
equipment
at once.
the
FCC about
Have the installation
regularly
interference, stop using the
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.
again.
filter airflow to unit.
can
S
OVERF~ATING
d~rnagePCboards~
Put on grounded wrist strap BEFORE
handling boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC
WELDING
can cause
Interference
~:::..:
Electromagnetic energy can interfere with
electronic equipment such as
computers and computer-driven equipment
sensitive
________
;~tnjury~
such
Be
Keep away from moving parts.
Keep away from pinch points
all equipment in the welding
electromagnetically compatible.
such
as
To reduce
drive
possible,
rolls.
WIRE
can cause
~
Do not press gun
trigger
sure
area
is
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
close
Locate welding operation 100 meters from any sensitive elec
tronic equipment.
~
~WELt~NG
robots.
as
___________
~n~ury
Be
:...,,...,,,..,,--~
this
sure
according
until instructed to do
welding
machine is installed
and
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
such
point gun toward any part of the body,
people, or any metal when threading
welding wire.
using line filters,
Do not
or
shielding the work
area.
other
~
1~4~.~P~afetY
~
~
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 NW. LeJeune Rd, Miami, FL 33126
National Electrical
Code, NFPA Standard 70, from National Fire
Batterymarch Park, Quincy, MA 02269.
Protection Association,
.~
Safe
~,,,.
Handling
of
~
Compressed Gases
in
Cylinders,
P-i, from Compressed Gas Association,
Highway, Suite 501, Arlington, VA 22202.
1235
CGA
Pamphlet
Jefferson
Davis
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For
Occupation
And Educational
Eye
And Face
Protection, ANSI Standard Z87.i, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-186 989
Page
3
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
1.
Keep
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
committees 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
2.
Arrange
3.
Do not coil
examined. Until the final conclusions of the research
may wish to minimize your exposure to
welding
cutting.
To reduce magnetic fields
procedures:
are
reached, you
electromagnetic
Page
4
cables to
or
together by twisting
one
drape
or
taping
side and away from the
cables around your
Keep welding power
practical.
source
Connect work
to
and cables
them.
operator.
body.
as
far away from opera-
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
fields when
About Pacemakers:
or
OM-186 989
4.
cables close
in the
workplace,
use
the
following
Pacemakerwearersconsultyourdoctorfirst. If cleared byyourdoctor,
following the above procedures is recommended.
then
~.
SECTION 1
-
CONSIGNES DE SECURITE
UTI LISATION
LIRE AVANT
-
som
1-1~!Sig~tfr~ati~ do sym~1es
~fl ~
~
~
~
.&~-
Signifie Mise en garde! Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
a
message de sØcuritØ
A
Identifie
U~
Sign/tie NOTA
tin
~
~
Ce groupe de symboles signifie Mise en garde I Soyez vigilant Ily a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
MOUVEMENTet aux PIECES CHAUDES. Reportez-vous aux symboles
partlculler.
et aux directives ci-dessous afin de connaitre les mesures a
Øviter tout
nest pas re/at/f a /a sOcuritØ.
A
~~soudage a I~arc
dØvlter tout
de sØcuritØ prØsentØes ci-aprŁs ne font
que resumer iinformation contenue dans lea normes de sØcuritØ
enumerees a Ia section 1-5. Veuiilez lire et respecter toutes cea
normes de sØcuritØ.
et suivez las directives mentionnees atm
A
Lea
consignea
Linstailatlon,
iutiiisation,
vent Œtre conflØs
A
qu
ientretien
reparations
qualifiees.
ne
dol
plus
par
et ies
des personnes
Au cours de iutiiisation, tenirtoute personne a iØcart et
tlcuiierement ies enfants.
Ne pas toucher lalectrode quand on est en contact avec Ia
ou une electrode provenant dune
autre machine.
~
Un
simple
contact avec des
I
piŁces Ø!ectriques peut
provoquer une electrocution ou des blessures graves.
LØlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrŁe et les
circuits internes de lappareil sont agalement sous
tension ace moment-Ia. En soudage semi-automatique ou automatique,
Ie fil, le dŁvidoir, le logement des galets dentrainement et les piŁces
mŁtalliques en contact avec le fil de soudage sont sous tension. Des
matŁriels mal insta!!es ou mal mis a Ia terre prŁsentent un danger.
Ne
jamais
toucher les
piŁce,
Ia
terre
Nutiliser
materiel
quun
en
bon Łtat.
RØparer
ou
remplacer
sur-le
champ les piŁces endommagŁes. Entretenir Iapparell conformŁment
ace manuel.
Porter
un
harnais de sŁcuritŁ
Maintenir solidement
en
quand
place
on
travaille
en
hauteur.
tous lea panneaux et
capots.
Fixer le cAble de retour de faon a obtenir un bon contact mŁtal-mŁtal
avec Ia piŁce a souder ou Ia table de travail, le plus prØs possible de Ia
soudure.
Isoler Ia
~t,NtHocELEe~iiUt
:rNt~1tc~..tr
.
Lea symboles prCsentes ci-aprØs sont utlilsØs tout au long du
present manuel pour attirer votre attention et identifier lea
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant
danger.
prendre pour
danger.
~t~t~11tt~1t
Dangers relatlfs
~i-2
_nd_Fre 4/97
avec
pince de masse quand
objet metallique.
pas mis a Ia
piŁce
pour Łviter Ia contact
tout
Ily a DU COU RANT CONTINU IMPORTANT dans les
convertisseurs aprØs (a suppression de (alimenta
tion Ølectrique.
ArrOter les convertisseurs, dŁbrancher le courant Łlectrique, et de
charger les condensateurs dalimentation selon les instructions
indiquŁes dans Ia partie entretien avant de toucher es piŁces.
piŁces Łlectriques sous tension.
protection secs ne comportant
Porter des gants et des vŁtements de
pas de trous.
de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŁcher le contact phy
sique Łventuel avec Ia piŁce ou Ia terre.
Sisoler
Ne pas
servir de source alectrique acourant Łlectrique dens es
dans les endroits confines ou lŁ o on risque de tomber.
se
humides,
Se servir dune
procØde
de
source
soudege
Łlectrique
acourant
Łlectrique
inhalation
zones
votre tŒte des fumŁes. Ne pas
les fumŁes.
Eloigner
UNIQUEMENT si le
le demande.
Si lutilisation dune source electrique acourant Łlectrique savare naces
se servir de Ia fonction de te!ecommande si lappareil en est equipŁ.
saire,
Couper lalimentation ou arrŒter le moteur avant de procŁder a Iinstal
lation, a Ia reparation ou a lentretien de lappareil. DŁverrouiller
lalimentation selon Ia norme OSHA 29 CFR 191 0.147 (voir normes
de sŁcuritŁ).
Installer et mettre ala terre correctement cet appareil conformŁment a
et aux codes nationaux, provinciaux et
son manuel dutilisation
municipaux.
Verifier et sassu
Toujours verifier Ia terre du cordon dalimentation
que Ie fil de terre du cordon dalimentation est bien raccordŁ a Ia
borne de terre du sectionneur ou que Ia fiche du cordon est raccordŁe
a une prise correctement mise a Ia terre.
rer
En eftectuant lea raccordements dentrŁe fixer dabord le conducteur
de mise a Ia terre appropriŁ et contre-vŁrifier les connexions.
Verifier
frŁquemment le cordon dalimentation pour voir sil nest pas
endommagŁ ou dŁnudŁ remplacer le cordon immŁdiatement sil est
endommagŁ un cable dŁnudŁ peut provoquer une electrocution.
Mettre lappareil hors tension quand on ne lutilise pas.
Ne pas uti!iser des cables uses, endommagŁs, de grosseur insuffi
sante ou mal apissŁs.
Ne pas enrouler lea cAbles autour du corps.
Si Ia piŁce soudŁe doit Łtre mise a laterre, le faire directementavec un
cAble distinct
ne pas utiliser le connecteur de piŁce ou le cable de
retour.
etdes g~. Leur
votre sante.
peut Øtre dangereux pour
A
respirer
lintŁrieur,
veau
ventiler Ia zone et/ou utiliser un echappement au ni
de Iarc pour levacuation des fumŁes et des gaz de soudage.
Si Ia ventilation est insuffisante, utiliser
tion dair homologuŁ.
un
respirateur
a alimenta
Lire les specifications de sŁcurite des materiaux (MSDS5) et les ins
tructions du fabricant concernant les mŁtaux, les consommables,
les revŒtements, les nettoyants et tes dŁgraisseurs.
espace fermŁ seulement siI est bien ventilŁ ou
dair. Demander toujours a
un surveillant dUment formØ de se tenir a proximite. Des fumŁes et
des gaz de soudage peuvent dŁplacer lair et abaisser le niveau
doxygene provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration ne prØsente aucun danger.
Travailler dans
en
portant
un
un
respirateur a alimentation
Ne pas souder dans des endroits situŁs a proximitŁ dopØrations de
de nettoyage ou de pulverisation. La chaleur et lea
rayons de iarc peuvent reagir en presence de vapeurs et former
des gaz hautement toxiques et irritants.
dØgraissage,
Ne pas souder des metaux munis dun revŒtement, tels que lacier
en plomb ou au cadmium a moms que le revŒte
ment nait ate enlevØ dans Ia zone de soudure, que Iendroit soit
bien ventile, et si nØcessaire, en portant un respirateur a alimenta
tion dair. Lea revØtements et toua lea mŁtaux renfermant ces ele
ments peuvent dØgager des fumØes toxiques en cas de soudage.
galvanisO, plaque
OM-1 86 989
Page
5
~
/
~
~
L~S RAVONS DE L~ARC peuveM
v~quer des brluros dans lea yeux~t
~
.~..)
..
de larc du procØdØ de soudage
genŁre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brUlures dans les yeux et sur Ia peau. Des Øtincelles sont projetØes
pendant
0
Le
rayonnemont
soudage.
I~J
Former Ialimentation
non utitisation.
Veitter
toujours a bien
rateur dadduction
Porter un casque de soudage muni dun Øcran de filtre appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49.1 et Z87.1 ØnumØrØ dans les normes de sØcuritØ).
Porter des
protections approuvØs pour
du gaz
aØrer los ospaces confines
dair
protecteur
ou se
en cas
servir dun
do
respi
homologue.
.DES..PIE~ESeU~pro-j
les oreilles site niveau sondre est
~
trop ØlevØ.
______
Utiliser des Øcrans ou des barriŁres pour protØger des tiers de lØclair
et do lØblouissement; demander aux autres personnes de ne pas re
garder arc.
Porter des vØtements de
ble, resistant
au
feu
(cuir
We pas toucher dos
parties
chaudes ~ mains
nuos
____________
PrØvoir une pØriode do rofroidissomont avant
dutiliser le pistolet ou Ia torche.
protection constituŁ dans une matiŁre dura
ou lame) et une protection des pieds.
~
LE SOUDAGE peufl?ovoquer
Incendle ou~~pj~n~
~
1
~s
un
~MAGN~ES~p~uiIŁitj
~
soudage effectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
Le
Des Øtincelles peuventŒtre
do larc de soudure. La projection dØtincel
les, des piŁces chaudes et des Øquipements chauds pout provoquer des
incendies et dos brOlures. Lo contact accidentel de IØlectrode avec des
objets metalliques peut provoquer des Øtincelles, une explosion, un
surchauffement ou un incendie. Avant do commencer le soudage,
verifier et sassurer quo lendroit no prØsente pas de danger.
provoquerleurØclatement.
cardiaque, restez a distance.
porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sapprocher
des operations do soudago Ł larc, do gougoago ou
de soudago par points.
Portours do stimulatour
projetØes
Se
proteger
et dautros
personnes de Ia
projection
dØtincettes
Les
et de
metal chaud.
Ne pas souder dans un endroit l o~i des Øttnceltes
sur des substances mnflammables.
peuvent tomber
Le bruit des processus et des
loule.
DŁplacer toutes les substances inflammables a une distance de 10,7
m de larc do soudage. En cas dimpossibilitØ los recouvrir soigneuse
mont avec des protections homologues.
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
ment passer dans dautres zones en traversant de petites fissures et
Porter des
Øquipements pout
protections approuvØs
affecter
pour los oreitles si
10 niveau sondre est trop ØlevØ.
des ouvertures.
SurveillertoutdØclenchementdincendie ettenir
un
extmncteurproxi
~~
~
S~ des BOUTEILLES sont endomma- I
mite.
soudage effectuØ sur un plafond, plancher, paroi ou separation
peut dØclencher un incendie do lautre ctØ.
No pas effectuer le soudage sur des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naiont eta prØpa
Le
rØs correctement conformØmertt a AWS F4.1
(voir
los
normes
Brancher le cable sur Ia piŁce le plus prŁs possible do Ia zone do sou
dage pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Łvontuols en provoquant des risques dØlec
trocution et dincendie.
posto de soudage pour dØgoler des conduitos go
lees.
utilisation, enlever Ia baguette dOlectrode du porte
couper le fil a Ia pointe do contact.
Porter des vŒtements do protection dØpourvus dhuile tels quo des
gants en cuir, une chemise en matØriau lourd, dos pantalons sans re
vers, des chaussures hautes et un couvre chef.
En
cas
de
electrode
non
ou
Avant de souder, retirer toute substance combustible do
telles quun allumeur au butane ou des allumettes.
vos
poches
protecteur contiennent du gaz
pression. Si une bouteitle est endomma
gee, elle pout exploser. Du fait quo los bouteilles do gaz
font normaloment partme du procØdØ do soudage, los
Des bouteilles de gaz
sous haute
de
sØcuritØ).
Ne pas utilisor 10
~
_____________
manipuler
avec
precaution.
les bouteilles do gaz comprimØ dune chaleur excessive,
des chocs mecaniques, du laitier, des flammos ouvortes, des Øtin
ProtØger
cellos ot des arcs.
Placer los bouteilles debout en los fixant dans un support station
naire ou dans un porto-bouteilles pour les empŒcher de tomber ou
do so renverser.
Øloignees
Tenir los bouteilles
cuits electriques.
No
jamais placer
une
Une electrode de
uno bouteillo.
No
jamais
souder
des circuits de
torche do
soudage
une
no
bouteille
soudage
doit
soudage
sur une
jamais
ou autres
cir
bouteille a gaz.
entrer en contact avec
pressurisØe
risque dexplosion.
Utiliser seulement des bouteifles do gaz protoctour, regulateurs,
tuyaux et raccords convenablos pour cette application spØcifique;
los maintenir ainsi que les ØlŁments associŁs en bon etat.
Ne pas tenir Ia tŒte
bouteille.
Lo soudage, lØcaillement, 10 passage do Ia piŁce
a Ia brosse en fil do for, ot 10 meulage genŁrent
des Øtincelles etdes particules mØtalliques volan
tes. Pendant Ia
do
projoter
pŁriodo
do refroidissement des souduros, elles
risquent
du laitior.
Porter des lunettes de sØcuritØ
OM-i86 989 Page 6
avec
Øcrans latØraux
ou un
Øcran facial.
en
face do Ia sortie
en
ouvrant Ia soupapo do Ia
Maintenir le chapeau do protection sur Ia soupape, sauf
dutilisation ou do branchoment do Ia boutoille.
en cas
Ure et suivre los instructions concernant los bouteilles do gaz cornprime, los equmpements associØs et los publications P-i CGA Łnu
mØrØes dans los rtormes do sØcuritŁ.
~~et ia
~enance~\~ ~
~a
___
~en
No pas
placer lappareil sur, au-dessus
proximitŁ do surfaces infllammables.
ou
Rester a lØcart des organes mobiles
a
Maintenir fermØs et fixement on
Ne pas installer lappareil a proximitØ de produits inflammables
Ne pas surcharger Iinstallation Ølectrique sassurer que lalimon
tation est correctement dimensionnØ et protØgØ avant de mettre
lappareil en service.
panneaux,
-
~
capacitØ appropriØo
pour
En utilisant des fourches de levage pour dOplacer lunitØ, sassurer
que los fourches sont suffisamment longues pour depasser du ctØ
de
~appareil.
-
-~:~:
-
-
Le rayonnement haute frequence peut provoquer
des interferences avec los Oquipements de ra
dionavigation et de communication, les services
de sOcuritØ et les ordinateurs.
Demander soulement a des personnes qualifiØes familiarisOes
des equipemonts electroniques de faire fonctionner linstalla
tion.
Lutilisateur est tenu do faire corriger rapidement par
les interferences resultant de linstallation.
pØriode
electrician
interferences, arrŒter immØdiatement lappa
Si le FCC
reil.
signale
Effectuer
regulierement
des
~.
de refroidissement, respec
nominal.
le contrle
et lontretien
do linstallation.
Maintenir soignousement fermØs los portes et les panneaux des
sources do haute frØquenco, maintenir los Øclateurs a une distance
corrocte et utiliser une terre et et un blindage pour rØduire los inter
fØrences Øventuelles.
cycle opØratoire
RØduire le courant ou 10
recommancer
S
un
qualifie
-
SUFFERUEQ~~
une
place les portes,
dispositifs de
avec
-
PrØvoir
et
-~--~:;.;-~
--~---~~~
L~EMPLOI EXCESSIF peut
ter le
recouvrements
:~AE. I
LE~ \~b~N
QUENCE (H~F~) risque d~provoquer I
~-;_J
deII~ferfere~
Litiliser lannoau do levage uniquement pour sou
lever lappareil, NON PAS les chariot, los bouteil
los do gaz ou tout autre accossoire.
oppose
le
protection.
I~f~
Utiliser un engin dune
soulever lappareil.
comme
ventilateur.
le
cycle opØratoire avant de
soudage.
Ne pas obstruer los passages dair du poste.
~
LE~CHARGES ELECTROSTATJQUES
~peuvent endommagerIesc1rcuftŁ1m-~
primØs~
Etablir
Ia connexion avoc Ia barrette de terre
avant do manipulor des cartes ou dos piŁces.
Utiliser des
pochettes
pour stocker, deplacer
circuits imprimes.
ot dos boItes antistatiquos
ou oxpedier des caries de
Lenergie
sapprocher
des organes mobiles.
de
lØquipement do Ia zone do soudago soit com
patible electromagnetiquement.
Pour rØduiro Ia possibilitØ dinterfØronce, maintenir les cblos do
soudage aussi courts quo possible, los grouper, et les poser aussi
bas que possible (ox. par terre).
Veiller Ø souder a une distance do 100 metres do tout Øquipement
electronique
No pas sapprocher des points de coincement
tols que des rouleaux de commande.
risque
Veiller ace que tout
sensible.
Voiller ~ ce quo
conformØment a
No pas
Ølectromagntique
provoquer des interferences pour lØquipement
electronique sensible tel que los ordinateurs et
lequipement commandØ par ordinateur tel que
los robots.
co
posto do soudago soit pose
ot mis a Ia terre
mode
domploi.
En cas dintorfØrences aprŁs avoir pris les mesures prØcØdentos, 1
incombo a lutilisatour do prendre des mosuros supplementairos
tolles que le deplacement du posto, lutilisation de cAbles blindŁs,
lutilisation do filtros do ligne ou Ia pose de protecteurs dans Ia zone
ce
de travail.
peuventpro~
--~---~-
Portours do stimulateur
Ne pas appuyer sur Ia
recu linstruction.
Ne pas
sonnes
le fil de
le
gachette
avant den avoir
pistolet vers soi, dautres per
ou toute piŁce mØcanique en engageant
soudage.
diriger
cardiaquo,
restoz a dis
tance.
Los porteurs dun stimulateur cardiaque doivent
dabord consultor leur mØdocin avant do sappro
chor dos operations do soudage a larc, do gou
goage ou do soudago par points.
OM-186 989 Page 7
p1:~4~..~..prifl~.jpajesno
~
~
Safetyin Welding and Cutting, norme ANSI
ding Society, 550 NW. Lejeune Ad, Miami
~
de IAmerican WelFL 33126
Z49. 1
Safe
Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501,
Safetyand Health Sandards,
OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
VA 22202.
Regles de sØcuritØ en soudage,
coupage etprocØdØs connexes, nor
CSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
1 R3.
me
20402
Recommended Safe Practice forthe Preparation for Weldingand CutHeld Hazardous Substances, norme
ting of Containers That
AWS F4.1,del American Welding Society, 550 N.W. Lejeune Ad, Mia-
Have~
mi
Arlington,
FL 33126
Safe Practices For Occupation And Educational Eye And Face Protec
tion,
norme
1430
National Electrical Code, NFPA Standard 70, de Ia National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ANSI Z87.1, de lAmerican
Broadway,
New
National Standards Institute
York, NY 10018.
Cutting and Welding Processes, norme NFPA 51 B, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
Fire
th~rii~ii~:c
*
________
DonnØes
Afin de rØduire les
des
de travail,
sur le soudage Ølectrique et sur les effets, pour Iorganisme,
champs magnØtiques basse frØquence
Lextrait suivant est tire des conclusions
gØnerales du document intituBiological Effects of Power Frequency Electric & Magnetic Fields
(Washington DC: U.S. GovernBackground Paper, OTABPE53
ment Printing Office, mai 1989), publie par ie Office of Technology
Assessment du CongrŁs amØricain: a... ii existe maintenant d abondantes donnØes scientifiques compilØes a Ia suite dexpØriences sur
Ia cellule ou dØtudes sur des animaux et des humains, qui montrent
clairement que les champs electromagnetiques basse frØquence peudes effets sur lorganisme
et mØme y produire des
transformations. MŒme sil sagit de travaux de trŁs grande qualite, les
met pas dØtabhr
un
tal~eau densemble
coherent P~e encore, eVe
ne
permet pas de tirer des conclusions finales concernant les risques Øventuels, ni doffrir des conseils sur les mesures a prendre pour
rØduire sinon Øliminer les risques Øventuels~. (Traduction libre)
nous
OM-186 989 Page 8
champs ØlectromagnØtiques
respecter les consignes suivantes
dans Ienvironnement
1
Garder les cables ensembles en les torsadant
attachant avec du ruban adhØsif.
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
lØ
vent avoir
________
ne
oppose
de
ou en
les
lopØrateur.
pas entourer pas les cables autour de
vous
4
Garder le poste de
de
5
soudage
et les cØbles le
plus
loin
possible
vous.
Relier Ia
pince
da
masse
le
plus prØs possible
de Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardlaques
LesconsignesmentionnØesprØcØdemmentfontpartiedecellesdesti
nØes aux personnes ayant recours a un stimulateur cardiaque.
Veuillez consulter votre mØdecin pour obtenir
plus
de details.
SECTION 2- INSTALLATION
NOTE
Amperage
Range
(Phoenix
Rated
input
Welding
Output
Power
manuaL
Phase
60%
Amperes Input At Rated
Load Output 60 Hz,
Maximum
Voltage
Range
456 CC/
CV Only)
Open-Circuit
Voltage DC
Three-Phase
575 V
I
KVA
KW
I
450A@38VoltsDC, 100%
Duty Cycle;
565 A @ 43 Volts DC,
Three
2-2.
throughout this
Specifications
2-1.
*While
Unless otherwise noted, the Invision 456P is shown
}~~
600
5
10 38
95
24.4
24.3
I
19.0
(0.12*)
(0.12*)
I
(0.07k)
I
Duty Cycle
idling
Duty Cycle
and
Overheating
I
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
-
SW
-~-
I
4W
3 PHASE
-
If
unit
w
~ 3W
<
2W
overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
-
-
-J
A Exceeding duty cycie
damage unit and void
-
can
war
ranty.
100
-
0
-
10
202530
15
40
~~7080~1J0
% DUTY CYCLE
100%
Duty Cycle
At 450
Amperes
60%
Duty Cycie At 565 Amperes
0
Continuo us
Welding
Overheating
~~AjV
~
~
*
5
~
III, ~lI
OR
Minutes
Reduce
Duty Cycle
dutyl 4/95
-
SA 181 560
CM-i 86 989
Page
9
2-3.
Volt-Ampere Curves
Volt-ampere
Invision 456P and Phoenix 456
curves
show
mini
voltage and
amperage output capabilities of
unit. Curves of other settings fall
mum
(CV Only)
and maximum
between
curves
shown.
100
80
w
60
MAX.
40
20
0
0
100
200
300
400
500
600
700
AMPERAGE
Phoenix 456
(CC Only)
100
80
Ui
60
40
20
0
100
200
300
400
500
600
700
AMPERAGE
va_curvel 4/95
OM-186 989
Page
10
SA-181 581 / SA~181 562
2-4.
Dimensions And
Weight
Layout Dimensions
Hole
A
14-21/64 in (363.9 mm)
B
20-3/4 in (527.1 mm)
F
28 in
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.
18 in
(457 mm)
Weight
118 lb
(53.5 kg)
Tipping
A
Do not
move or
operate
unit where it could
tip.
3
Location
Lifting
1
~fr/~
5
Use
lifting
Forks
forks to
Extend forks
of unit.
2
Lifting
move
unit.
beyond opposite side
Handles
Use handles to lift unit.
Hand Cart
3
4
Use cart
unit.
or
similar device to
move
4
Rating
Label
Use
rating
label to determine
input
power needs.
5
18
Une Disconnect Device
Locate
unit
power
supply.
near
input
correct
A Special installation may be
required where gasoline or
volatile liquids are present
NEC Article 511
Section 20.
see
Ioc_2 3196-
or
CEC
ST-800 811 / Ret. ST-801 718
OM-186 989
Page
11
2-6.
Weld
Output
Terminals and
Selecting
Cable Sizes
Total Cable
(Copper) Length
lOOft(30m)OrLess
150ft
I
200ft
(45m)
j
(60m)
60100%
10-60%
In Weld Circuit Not
I
I
250ft
I
300tt
(70m)
10
Exceeding
100%
I
350ft
400ft
(105m)
(90m)
(120m)
Duty Cycle
Duty Cycle
Duty Cycle
4
4
4
3
2
1
1/0
3
3
2
1
1/0
2/0
3/0
3
2
1
1/0
2/0
3/0
4/0
2
1
1/0
2/0
3/0
4/0
2-2/0
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
.
Weld cable size (AWG) is based
2-7.
Remote 14
on
either
a
4 volts
or
less
drop
or a
current
density of
at least 300 circular mils per ampere.
S-0007-D
Receptacle Information
REMOTE 14
Socket*
Socket Information
A
24 volts
B
Contact closure to A
tactor control circuit.
I
115 volts
ac.
Protected
24 VOLTS AC
~
OPIPUT
(CONTACTOR)
ac.
by
OUTPUT
J
(CONT~TOR)
Protected
Contact closure to I
24 volts
completes
by
115 VOLTS AC
~,
circuit breaker CB2.
ac con
circuit breaker CB1.
completes
115 volts
ac con
tactor control circuit.
C
Output
to remote
control; +10 volts dc in MIG
mode. For Phoenix 456
only:
0 to +10 volts dc in
other modes.
REMOTE
CONTROL
0
Remote control circuit
common.
E
0 to +10 volts do
command
input
signal from
re
mote control.
/e
A/V
AMPERAGE
VOLTAGE
M
Mode select.
N
Remote inductance control.
F
Current
H
Voltage feedback;
G
Circuit
K
Chassis
feedback;
common
remaining
OM-186 989
sockets
Page
12
are
not used.
+1 volt do per 10
for 24 and 115 volts
GND
*The
+1 volt dc per 100 amperes.
common.
arc
ac
volts.
circuits.
2-8.
115 Volts AC
Duplex Receptacle
And Circuit Breakers
1
ll5VlOAACReceptacle
Power is shared between duplex
receptacle and Remote 14 recep
tacle (see Section 2-7).
2
Circuit Breaker CB1
3
Circuit Breaker CB2
CB1 protects duplex receptacle
and 115 volts ac portion of Remote
14 receptacle from overload.
CB2 protects 24 volts
Remote
14
of
from
portion
ac
receptacle
overload.
Press button to reset breaker.
0
___
___
ST.801 524-B
2-9.
Electrical Service Guide
Three-Phase
Input Voltage
575
Input Amperes At Rated Output
24.4
Max Recommended Standard Fuse Or Circuit Breaker
Mm
Input Conductor Size
Max Recommended
Mm
input
In
Rating
In
Amperes
35
10
AWGIKcm1I
Conductor
Grounding Conductor Size
in
Length
In Feet
AWG/Kcmll
Reference: 1993 National Electrical Code
(Meters)
371
(113)
10
(NEC).
S-0092J
OM-186 989
Page
13
2-10. Connectii
Turn
Off welding
source, and check
A
power
voltage
input capacitors accord
ing to Section 4-3 before
proceeding.
on
Strain Relief Connector
1
Clamp
Obtain and install proper
connec
tor.
Input And Grounding
Conductors
2
Select size and length using Sec
2-9. Connect as shown in
illustration.
tion
3
Line Disconnect Device
See Section 2-9.
Reinstall
right
side
panel.
3
2
=
GND/PE
A Always
Connections For
Standard Model
connect
grounding
conductor first.
Tools Needed:
cI:I:I::z:1===~iJ
5/16 in
ST-801 535-B! ST-801 822
OM-186 989
Page
14
SECTION 3- OPERATION
3-1.
1
Front Panel Controls For Invision 456P
Power Switch
The
fan
I
is
motor
controlled and
needed.
only
runs
thermostatically
when cooling is
2
Voltmeter
(see Section 3-3)
5
3
Ammeter
(see Section 3-3)
4
Voltage Adjustment
Inductance determines the wetness
of the
weld puddle. When set higher, wetness
(puddle fluidity) increases.
Control
Inductance Control
6
A/
ON
________
I~
-e
OFF
VOLTAGE ADJUST
POWER
MADE IN
UCA
!ANGE5
REMOTE
ST-180 306-C
3-2.
Mode and
Voltage Control
For lnvision 456P
1
Remote 14
Receptacle
Mode Control
The unit defaults to standard MIG
mode. When a suitable external
control is attached to the
Remote 14 receptacle, 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 operation.
pulsing
Voltage Control
The unit defaults to Panel control of
output voltage. When a suitable re
mote voltage control or pulsing
control is attached to the Remote
14 receptacle, the remote device
assumes control of output voltage.
To return to Panel control of volt
age, disconnect or disable any re
mote devices that send an input to
pin E.
ST-801 192
OM-1 86989
Page
15
3-3.
Meter Functions For Invision 456P
N OT E
The meters
after the
display the actual weld output values
Meter
Mode
for approximately three seconds
is broken.
arc
Reading
Meter
At idie
Reading
While
Welding
A
I
MIG
24.5
24.5
Preset Volts
1
Amps
12501
Actual Volts
Display
I
Actual
Amps
Front Panel Controls For Phoenix 456 CC/CV
Power Switch
~ The
Pulse
Display
Actual
24.51
IPPPI
Pulse
3-4.
Actual Volts
Blank
Pi~sed
250
fan
is
motor
control/ed and
only
runs
thermostatically
when coo/mg is
needed.
(see
Section
3-5)
(see
Section
3-5)
set towards
6
maximum, short-circuit am
perage is increased at low arc voltage to assist
with arc starts as well as reduce sticking while
welding (see volt-ampere curves in Section
Mode Switch
2
3
Ammeter
4
V/A (Voltage/Amperage) Adjust Control
5
Voltage/Amperage
Control Switch
panel control, place switch in Panel
position and use the V/A Adjust control.
For front
control, make connections
to Re
receptacle, and place switch in Re
mote position. In most modes, remote control
is a percent of the V/A Adjust control setting.
Value selected on V/A Adjust is maximum
setting
determines both the
process arid output On/Off control (see Sec
tion 3-6). Source of control (panel or remote)
for the amount of output is selected on the V/A
minimum, short-circuit amperage
voltage is the same as
normal weld
ing amperage.
2-3).
Control switch.
Select
For Air Carbon Arc
Control adjusts inductance when MIG position
is selected on the Mode switch. Inductance
determines the wetness
of the weld puddle.
When set towards maximum, wetness
(puddle fluidity) increases.
(CAC-A) cutting and goug
ing, place switch in the Stick position. For best
results, place Inductance/Dig control in the
maximum
position.
mote 14
7
Inductance/Dig
Control adjusts
Control
Dig
mode is selected
on
when the Stick or CC
the Mode switch. When
setting
best suited for
application.
MIG, or one of the TIG modes is
selected, this control is not functional.
When Pulsed
A
ON
I
at low arc
When set towards
The Mode switch
Voltmeter
For remote
available on remote. In the MIG mode, remote
control provides full range of unit output re
gardless of V/A Adjust control setting.
___
-e
0
V/A ADJUST
POWER
MADE IN
PANEL
1NDUCTANC\\DIG
7
z
REMO\
5
ST-179 542-B
OM-186 989
Page
16
3-5.
Meter Functions For Phoenix 456 CCICV
NOTE
1II~
The meters display the actual weld output values for approximately three seconds
after the arc is broken.
Mode
Meter
Reading
At idle
7.0
Uft-ArcTIG
Meter
85
Actual Volts
Preset
Reading While Welding
10.3
Amps
85
Actual Volts
Actual
Amps
V
I
TIG
Blank
85
10.3
Amps
Preset
Actual
Pulsed
A
Actual Volts
IPPPI
124.51
Pulse
Display
Display
Amps
250
Blank
Preset Volts
Pulse
85
24.5
24.5
MIG
Actual Volts
I
V
A
V
I
Actual Volts
Actual
Amps
I 2501
Actual
Amps
Actual
Amps
V
24.5
Preset
Blank
80.0
Stick
Actual Volts
3-6.
Mode Switch
NOTE
Mode Switch
~
Settings
Amps
85
(CCV)
Preset
1
Amps
I
Actual Volts
24.5
85
Actual Volts
Actual
For Phoenix 456 CC/CV
The Stick and CC modes provide the Adaptive Hot StartTM 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.
Setting
Output On/Off
Process
Lift-Arc TIG
GTAW
See Section 3-7
Control
Electrode Hot
TIG
GTAW With HF Unit, Pulsing Device,
Or Remote Control
At Remote 14
MIG
GMAW
At Remote 14
Pulsed MIG
CC
Stick
Amps
GMAW-P
(Requires
Stick
(SMAW)
an
external
pulsing device.)
With Remote On/Off
SMAW
At Remote 14
At Remote 14
Electrode Hot
CM-i 86 989
Page
17
3-7.
Lift-Arc TIG Procedure For Phoenix 456 CC/CV
With Mode switch in the Uft-Arc
TIG position, start an arc as
follows:
1
2
-c~
TIG Electrode
2
Workpiece
Touch
tungsten
piece
at
weld
electrode to workstart
point,
hold
electrode to workpiece for 1-2
seconds, and slowly lift electrode.
An arc will form when electrode is
12
Touch
1
Seconds
lifted.
o~o
Normal
~
open-circuit voltage
is not
present before tungsten electrode
touches
workpiece; only
sensing voltage
i0 0!~0 0.
is
a
low
present be
electrode and workpiece.
The solid-state output contactor
does not energize until after elec
trode is touching workpiece. This
allows electrode to touch worktween
piece
sticking,
Do NOT Strike Like A Match!
without
or
getting
overheating,
contaminated.
Ref. S-156 279
SECTION 4- MAINTENANCE AND TROUBLESHOOTING
Routine Maintenance
4-1.
~
F,1
A
~
I~
Disconnect power
before maintaining,
Maintain
during
3 Months
Replace
damaged
Repair or
replace
or
unreadable
label.
cracked
cables.
Repair or
replace cracked
Y/4
/
cables and cords.
-~
6 Months
Clean and
weld
terminals.
Blow out
tighten
OM-186 989
inside.
Page
18
Replace
cracked
torch body.
more
severe
often
conditions.
j
4-2.
Blowing Out
Inside of Unit
A
Do not
remove case
blowing
To
blow
through
out
when
out inside of unit.
unit, direct airflow
front and back louvers
as
shown.
Ret ST-8O1 716
OM-186 989
Page
19
4-3.
Removing Case and Measuring Input Capacitor
A Significant
voltage can remain on capacitors
Always check the voltage as shown
input capacitors have discharged be
DC
after unit is Off.
to be sure the
fore
working
on
unit.
Turn Off welding power source,
and disconnect input power.
1
Right Side
Panel
remove panel, remove
securing panel to unit.
To
screws
2
Interconnect Board PC2
3
Voltmeter
Measure the dc voltage across the
screw terminals on PC2 as shown
until voltage drops to near 0 (zero)
volts.
Proceed with
stall
cz1===~n
cover
job
inside unit. Rein
when finished.
5/16 in
Ref. ST-801 718! Ref. ST-801 536-A
OM-186 989
Page
20
4-4.
Voltmeter/Ammeter Help Displays
V
A
~ All directions are in reference
to the front of the unit. All cir
cuitry referred to is located
inside the unit.
1
Help
Indicates
1
a
Display
malfunction in the
pri
_______________
mary power circuit. If this display is
shown,
V
A
contact
a
Factory
Autho
rized Service Agent.
2
Help
2
Display
Indicates a malfunction in the ther
mal protection circuitry located on
the left side of the unit, If this dis
play is shown, contact a Factory
Authorized Service Agent.
V
A
3
Help
3
Display
Indicates the left side of the unit
has overheated. The unit has shut
down to allow the fan to cool it (see
Section 2-2). Operation will contin
ue when the unit has cooled.
4
V
A
________________
Help
4
Display
Indicates a malfunction in the ther
mal protection circuitry located on
the right side of the unit. If this dis
play is shown, contact a Factory
Authorized Service Agent.
5
Help
5
Display
Indicates the
V
A
~P
V
A
~
_______________
right side of the unit
has overheated. The unit has shut
down to allow the fan to cool it (see
Section 2-2). Operation will contin
ue when the unit has cooled.
6
Help
7
A
Help
A
7
Display
shut down.
Operation will
voltage is within
–15% of the operating range. If this
display is shown, have an electri
cian check the input voltage.
continue when the
8
V
Display
Indicates that the input voltage is
too high and the unit has automati
cally
V
6
Indicates that the input voltage is
too low and the unit has automati
cally shut down. Operation will
continue when the voltage Is within
–15% of the operating range. If this
display is shown, have an electri
cian check the input voltage.
Help
8
Display
Indicates
a
malfunction in the
sec
ondary power circuit of the unit. If
this display is shown, contact a
Factory Authorized Service Agent.
~
OM-186 989
Page
21
Troubleshooting
4-5.
F1~7f~~
Trouble
No weld output;
operative.
unit
Remedy
completely
in-
Place line disconnect switch in On
Check and
No weld
output;
meter
display
On.
replace
line
fuse(s),
Check for proper
input
Check, repair,
replace
or
position (see Section 2-10).
if necessary,
power connections
or
(see Section 2-10).
remote control.
Unit overheated. Allow unit to cool with fan On
Check voltmeter/ammeter
Erratic
or
improper weld output.
Use proper size and
Clean and
No 115 volts
ac
22
all weld connections.
at Remote 14
Reset circuit breaker CB2
(see Section 2-8).
ac
Page
(see Section 2-9).
(see Section 2-8).
No 24 volts
OM-186 989
of weld cable
Reset circuit breaker CB1
Remote 14
output
type
at
(see Section 2-2).
Help displays.
duplex
receptacle.
output
receptacle,
receptacle.
tighten
reset circuit breaker
(see
Section
2-10).
NOTES
CM-lBSONPap2S
SECTION 5- ELECTRICAL DIAGRAM
SI
Li
L2
13
R2 NTE~T ~J
III
flu
III
T2
ISV
~T
:~
c81
21
~
A
~
~
>
24V. ~vfr.
i~.cr. oir
~
~
I
<1
F~3
~
23.<
~
2.!<
~
I~1 ~TR3~ BJ
a~4
o
>
E>~N
F~2-fl
211
FC4MJ~23
EM1
21
H
>
~
>
<<~-9
1~V.
R.4T.
2*
~
~*
~-i
<~_1
tTNThCTO~
MIt
N
44
N
42rJi42J~
___
~
~
42
421
K>
________
Figure
OM-186 989
Page
24
5-1. Circuit
Diagram For Welding Power Source
C4
cVc2
zi
~EGAThE
SD-188 987-A
OM-186 989
Page
25
SECTION 6- PARTS LIST
U~ Hardware is
common
c~)
and
not available unless listed.
a,
~-
ST-801 744-D
Figure
OM-186 989
Page
26
6-1.
Complete Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
3
4
Ti
...7....
FM2
...8
PCi
187234..
1
126416
2
186984
C3-6
176 328
181925
13
Zi
180029
Li
180026
T2
185232
15
2
2
1
1
TRANSFORMER, HF
1
183918.. MOTOR, fan 24VDC 3000RPM 43CFM w/i 0 ohm resistor
186872.. CIRCUIT CARD ASSEMBLY, control
186933..
10....
Complete Assembly
COVER, top
HANDLE, molded plastic
126415
CLAMP~ saddle
+185212
PANEL, side
178551
INSULATOR, side
185835.. LABEL, warning electric shock
2
6
6-1.
Quantity
180105
is
CB2
093995
17
CB1
083432
...18
RC2
604176
1
1
BRACKET, mtg capacitor/PC board/fan
CAPACITOR, elctlt l800uf 500
INSULATOR, stabilizer lead
STABILIZER, output
INDUCTOR, input
1
4
1
1
1
TRANSFORMER, control 460/575VAC
BRACKET, mtg transformer aux
CIRCUIT BREAKER, man reset 15A
CIRCUIT BREAKER, man reset 1OA
1
1
1
1
1
27
177547
RECEPTACLE, str dx grd 3W 15A 120V
PLATE, identification (order by model & serial number)
COVER, receptacle weatherproof
PANEL, rear
LABEL, warning electric shock
BUSHING, snap-in nyl .750 ID x 1.000mtg hole
STAN D-OFF~ insul .25020 x 1.250 Ig
CONTACTOR, def prp 40A 3P 24VAC
CAPACITOR, polyp film .22uf 1000VAC
BUS BAR, capacitor
TRANSFORMER, current 500 turns
BUSHING, snap-in nyl CTMT 1.l25mtg hole
28
185214
BUS
187244
CIRCUIT CARD ASSEMBLY, interconnect
BUSHING, snap-in nyl 1.000 x 1 .375mtg hole
1
WINDTUNNEL, RH
1
1
175282
20
+179899
181181
153403
22
...23
24....
025248
Wi
180270
Ci,2
186875
25
...26
29
185992
CT1
P02
30
181271
179276
+185991
SRi
1
1
1
1
2
4
1
2
2
1
1
BAR,interconnecting
2
1
33.... PM1,2
RT1
34
184258
35
179930
36
179931
KIT, diode power module
KIT, transistor IGBT module
THERMISTOR, NTC 30K ohm @ 25deg C
HEAT SINK, power module
HEAT SINK, rect dual diode
37
179900
BASE
1
38
180271
BRACKET, mtg choke
GASKET, Dl-DT rubber
COIL, DI-DT
CORE, ferrite
CIRCUIT CARD ASSEMBLY, front panel (Invision 456)
CIRCUIT CARD ASSEMBLY, front panel (Phoenix 456)
TERMINAL, power output black
CAPACITOR, cer disc
BOOT, neg output stud
BOOT, pos output stud
PANEL, front
TERMINAL, power output red
NAMEPLATE, (order by model and serial number)
KNOB, pointer 1 .67Odia x .250 ID
KNOB, pointer .84Odia x .250 ID (Invision 456)
1
32
39
184260
173632
182654
40....
L3,4
180103
42
PC3
P03
182968
176844
...42
182964
182707
44....
07,8
186543
180732
46
179848
47
179898
...48
181245
179851
174992
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
OM-186 989
Page
27
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
174 992
Si
128 756
176 226
...50....HD1
168 829
179 928
...52....FM1
175 084
Ri,2
C9,i0,ii,12
175194
D1-4
179630
RT2
173632
6-1.
Quantity
Complete Assembly (Continued)
KNOB, pointer .84Odia x .250 ID (Pheonix 456)
SWITCH, tgl 3PST 40A 600VAC scr
INSULATOR, switch power
TRANSDUCER, current 1000A max
SHROUD, fan
MOTOR, fan 24VDC 3000RPM
2
1
1
1
1
53....
...54....
179826
179902
183827
179276
134327
PLG4
131 056
RC1O
166679
PLG2
115092
PLG7,19
PLG9,i1
PLG3,12
PLG5,15,16
115094
115091
RESISTOR/CAPACITOR
KlT~ diode ultra fast recovery
THERMISTOR, NTC 30A ohm @ 2sdeg C
INSULATOR, rectifier
WINDTUNNEL, LH
BUS BAR, output
BUSHING, snap-in nyl 1.000 x 1 .375mtg hole
LABEL, warning general precautionary
HOUSING
HOUSING
HOUSING
HOUSING
HOUSING
RECEPTACLE & SOCKETS
RECEPTACLE PINS & SOCKETS
2
1
1
1
1
2
2
1
1
PLUG & SOCKETS
.1
PLUG & SOCKETS
.1
PLUG & SOCKETS
.1
PLUG, w/Ieads voltage feedback
175026
PLUG, w/Ieads
PLG21
181410
PLUG, w/leads
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
180776
2
.1
.1
1
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-186 989
Page
28
(Equipment with
This limited
LIMITED WARRANTY
below, Miller Electric
werrents
its
to
equipment sold
a
Effective January 1, 1997
seriai number preface of KH
retail
purchaser
that
new
after the effective date of this limited
is free of defects in material and
*
workmanship
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 North American
distributor or eighteen months after the equipment is sent to
an International distributor.
2.
Original
Inverters
3 Years
and output rectifiers
only)
Parts and Labor
Transformer/Rectifier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Invertar Power
*
Intellitig
Power Sources
Supplies
Robots
the
Motor Driven Guns
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
(w/exception
of
Spoolmate 185)
IHPS Power Sources
*
HF Units
*
Grids
Spot
*
Load Banks
*
SDX Transtormars
*
Miller
*
Running Gear/Trailers
*
Plasma
Cyclomatic Equipment
Cutting Torches (except APT,
Models)
ZIPCUT &
PLAZCUT
Deutz
*
Field
Engines (outside
are
installed in,
4.
6 Months
5.
90
*
Days
or
for
North
a
greater.)
Batteries
Parts and Labor
MIG Guns/fIG Torches
Warranty
shall not
apply
by
the manufacturers
warranty,
Consumable components; such
as
if any.
contact
tips, cutting
nozzles, contactors, brushes, slip rings, relays
that feil due to normal
3.
to:
Equipment
or
parts
wear.
that has been modified
by
any party other
than
Miller, or equipment that has bean 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
for the
operation
equipment.
outside
of the
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 customers risk and expense. Millers option of
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
TO THE EXTENT PERMUTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
America)
minimum of
one
Some states in the U.S.A. do not allow limitations of how
long
implied warranty lasts, or the exclusion of incidental,
or
indirect, special
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.
an
Options
(NOTE: Field options are covered under True Bluefi
for the remaining warranty period ot the product they
whichever is
True Bluefi Limited
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
MIGHT
ARISE
BY
PROVISION,
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
RESPECT
TO
ANY
AND
PURPOSE, WITH
ALL
EOUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
Welders
*
(No labor)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These itams are
covered
2.
Parts
185
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND
ANY
IMPLIED
WARRANTY, GUARANTY OR
Systems
*
Spoolmate
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEOUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
Orbital Weld Heads
Water Coolant
*
Kits
allowed.
Parts and Labor
*
*
Replacement
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
*
1 Year
*
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EOUIPMENT.
main power rectifiers
Cutting
Accessory
specifications
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
engine manufacturer.)
3.
1.
3 Years Labor
(input
Remote Controls
*
Millers
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.
*
*
warranty
MERCHANTABILITY AND FITNESS.
*
other
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
et the time it is
Within the
5 Years Parts
no
Torches
Miller
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
INCLUDING
THE
WARRANTIES
OF
IMPLIED,
1.
newer)
warranty supersedes all previous Miller warranties and is exclusive with
guarantees or warranties expressed or implied.
Subject to the terms and conditions
Mtg. Co., Appleton, Wisconsin,
original
or
year
In Canada,
legislation
additional
warranties
in
provinces provides for certain
remedies other than as stated
herein, end 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
province.
some
or
be available,
but may vary from
province
to
millarwarr 5/07
Owners 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
Slate
lip
Resources Available
Always provide Model Name and Serial/Style Number.
Coutact your Disirihiltor for:
To locate distributor nearest you call
1-800-4-A-Miller.
Welding Supplies and Consumables
Options
and Accessories
Personal
Safety Equipment
Service and
Miller Electric
Repair
Mfg.
An Illinois Tool Works
Replacement
Parts
1635 West
Appleton,
Training (Schools, Videos, Books)
Owners
Spencer
Co.
Company
Street
WI 54914 USA
International
HeadquartersUSA
Phone: 414-734-9821
Manuals
USA & canada FAX: 414-735-4134
Technical Manuals
and
a
International FAX: 414-735-4125
European Headquarters
United Kingdom
Phone: 44 (0) 1625-525556
FAX: 44 (0) 1625-537553
Diagrams
Welding
File
information
Parts)
Circuit
Contact the DeilverinD Carrier for:
(Servicing
Process Handbooks
claim for loss
or
damage during ship
ment.
For assistance in
filing
contact your distributor
manufacturers
settling claims,
and/or equipment
or
Transportation Department.
f//A Miller.
PRINTED IN USA
'
The Power ~fB1ue.
1997 Miller Electric
Mfg. Co.
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