Related Manuals for Miller Electric 4500 Series
Summary of Contents for Miller Electric 4500 Series
- Page 1 Blu-Fab 3500 and 4500 Series OWNER’S MANUAL OM-221 677C 2006−07 Effective with serial number 222 842 Processes MIG (GMAW) Welding Flux Cored (FCAW) Description Arc Welding Power Source...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS−READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. - Page 4 European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: ITW Welding Products Italy S.r.l. Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 European Contact Signature: Blu-Fab 3500/4500 Declares that this product: conforms to the following Directives and Standards: Electromagnetic Compatibility Directives: 89/336/EEC...
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Page 5: Section 1 − Safety Precautions−Read Before Using
DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. - Page 6 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.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. -
Page 8: Emf Information
1-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Definitions
SECTION 2 − DEFINITIONS Warning! Watch Out! There are possible hazards as shown by the symbols. 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. - Page 10 OM-221 677 Page 6 S-176 106 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. Consult rating label for input power requirements, and check power available at the...
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Page 11: Section 3 − Introduction
SECTION 3 − INTRODUCTION 3-1. Included with Your Unit Power Source Power Cord (4m) Work Cable and Clamp (4m) Running Gear 3-2. Specifications Rated Output Welding at 45% Duty Cycle Range Blu-Fab 3500 350 A 32 V 16-32 Blu-Fab 4500 450 A 37 V 14-37 3-3. -
Page 12: Section 4 − Installation
SECTION 4 − INSTALLATION 4-1. Selecting a Location Position unit so air can circulate. 4-2. Typical MIG Connections Power source Work clamp (connect to receptacle as shown) Cylinder (chain to running gear) Cylinder valve Open valve slightly so gas flow blows dirt from valve. Close valve. -
Page 13: Electrical Service Guide
4-3. Electrical Service Guide Input Voltage Input amperes at rated output Fuse or circuit breaker rating (max. rec) Input conductor size Grounding conductor size** ** Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations. 4-4. -
Page 14: Connecting Welding Gun And Weld Cable
4-6. Connecting Welding Gun And Weld Cable 4-7. Installing Wire Guide And Drive Roll Tools Needed: 3/8 in OM-221 677 Page 10 Euro Torch US Torch 1−2 Correct Alignment Incorrect Alignment Gun Securing Knob Gun Block Gun Outlet Wire Guide Loosen knob, insert gun into block. -
Page 15: Section 5 − Operation
SECTION 5 − OPERATION 5-1. Controls Power Switch 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. Indicator Lamp This lights up when the power switch is placed in the ON position. -
Page 16: Panel Controls
5-2. Panel Controls 5-3. Run-In Control and Burnback Control OM-221 677 Page 12 Voltage Control Purge Control 2T−4T Switch Power ON-OFF Torch Connection Circuit Breaker Gas In Connector Control Cable Connection 10 Weld Cable Connection Run-In Control Use control to set wire feed speed before arc initiation After arc initiation, wire feed speed is controlled by the wire feed speed... -
Page 17: Section 6 − Maintenance And Troubleshooting
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Replace o-ring in Electrode/Gas Output receptacle if cracked. 6 Months Blow out or vacuum inside. 6-2. Troubleshooting Trouble Remedy No weld output; fan does not run. Place line disconnect switch in On position (see Section 4-4). - Page 18 Notes OM-221 677 Page 14...
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Page 19: Section 7 - Electrical Diagram
SECTION 7 - ELECTRICAL DIAGRAM DIGITAL POSIZIONI 956142300_9−10−04 OM-221 677 Page 15... -
Page 20: Section 8 - Parts List
SECTION 8 - PARTS LIST 8-1. Main Assembly OM-221 677 Page 16 9/13/04... - Page 21 Item Dia. Part Mkgs....116121119 ....156002044 ....056072075 .
- Page 22 Hardware is common and not available unless listed April 19, 2006 Figure 8-2. Wire Feed Assembly OM-221 677 Page 18...
- Page 23 Item Dia. Part Mkgs....000058427 ....156032128 ....156018033 .
- Page 24 Hardware is common and not available unless listed Item Dia. Part Mkgs. Figure 8-3. Wire Drive Assembly (All Models) ....057010052 ....187 325 .
- Page 25 Notes...
- Page 26 Notes...
- Page 27 Effective January 1, 2006 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, ITW Welding Products Italy S.r.l., 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.
- Page 28 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2006 Miller Electric Mfg. Co. 1/06 TW Welding Products Italy S.r.l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy...