Miller Electric INVISION Invision 456P Owner's Manual
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Miller Electric INVISION Invision 456P Owner's Manual

Miller electric owner's manual welding generator invision 456p
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www.MillerWelds.com
Invision 456P
OM-185 648F
July 2001
Processes
MIG (GMAW) Welding
With Optional Equipment:
Pulsed MIG (GMAW-P)
Description
Arc Welding Power Source

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Summary of Contents for Miller Electric INVISION Invision 456P

  • Page 1 Invision 456P Visit our website at www.MillerWelds.com OM-185 648F July 2001 Processes MIG (GMAW) Welding With Optional Equipment: Pulsed MIG (GMAW-P) Description Arc Welding Power Source...
  • Page 2 ISO 9001 Quality System Standard. 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.

  • Page 3: 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 WARNING 1-4. Principal Safety Standards 1-5. EMF Information This product, when used SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION for welding or cutting, 1-1.
  • Page 4 Declaration of Conformity For European Community (CE) Products Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Invision Declares that the product: conforms to the following Directives and Standards: Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC...

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 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. 1-2.
  • Page 6 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).

  • 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

    1-5. 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 electro- magnetic 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’...

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique –...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Manufacturer’s Warning Label Definitions S-179 310 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand.
  • Page 14 = <60 OM-185 648 Page 10 > 60 s S-179 309-A Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off.

  • Page 15: Symbols And Definitions

    2-2. Symbols And Definitions Amperage Positive Remote Voltage Output Circuit Breaker Negative Protective Earth Inductance Voltage Input (Ground) 2-3. Manufacturer’s Rating Label S-184 765 OM-185 648 Page 11...

  • Page 16: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Specifications Input Rated Welding Power Output 450 A @ 38 Volts DC, 100% Duty Cycle; Three Phase 565 A @ 38 Volts DC, 60% Duty Cycle 3-2. Duty Cycle And Overheating 100% Duty Cycle At 450 Amperes Continuous Welding Overheating OM-185 648 Page 12...

  • Page 17: Volt-Ampere Curve

    3-3. Volt-Ampere Curve Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 – SA-181 562 OM-185 648 Page 13...

  • Page 18: Selecting A Location

    3-4. Selecting A Location Movement Location 18 in (460 mm) Dimensions And Weight 118 lb (53.5 kg) 14-1/2 in (368 mm) OM-185 648 Page 14 Tipping 18 in (460 mm) 26 in (660 mm) 15-1/2 in (394 mm) Y Do not move or operate unit where it could tip.

  • Page 19: Weld Output Terminals And Selecting Cable Sizes

    3-5. Weld Output Terminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual.

  • Page 20: Remote 14 Receptacle Information

    3-6. Remote 14 Receptacle Information C L N Ref. ST-801 718 *The remaining sockets are not used. OM-185 648 Page 16 Socket* 24 volts ac. Protected by circuit breaker CB2. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volts ac con- tactor control circuit.

  • Page 21: 115 Volts Ac Duplex Receptacle

    3-7. 115 Volts AC Duplex Receptacle 3-8. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size in AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size in AWG/Kcmil Reference: 1993 National Electrical Code (NEC).

  • Page 22: Connecting Input Power

    3-9. Connecting Input Power Tools Needed: 5/16 in Y Turn Off welding power source, and check voltage on input capacitors ac- cording to Section before proceeding. Check input voltage available at site. Remove left side panel. OM-185 648 Page 18 =GND/PE Y Always connect grounding conductor...

  • Page 23: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Front Panel Controls Power On/Off Switch The fan motor is thermostatically controlled and only runs when cooling is needed. 4-2. Mode And Voltage Control Voltmeter (see 4-3) Ammeter (see 4-3) Voltage Adjustment Control ST-184 761 Inductance Control Inductance determines the “wetness”...

  • Page 24: Meter Functions

    4-3. Meter Functions NOTE The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Preset Volts Pulsed Pulse Display OM-185 648 Page 20 Meter Reading At Idle 24.5 Blank Pulse Display Meter Reading While Welding 24.5 Actual Volts Actual Amps...

  • Page 25: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Damaged Or Unreadable Labels 5-2. Blowing Out Inside Of Unit Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables Clean Tighten Weld Terminals 6 Months Blow Out Inside Maintain more often during severe conditions.

  • Page 26: Removing Case And Measuring Input Capacitor Voltage

    5-3. Removing Case and Measuring Input Capacitor Voltage Y Significant DC voltage can remain on capacitors af- + lead to lower right terminal, – lead to upper right terminal Tools Needed: 5/16 in OM-185 648 Page 22 ter unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged be- fore working on unit.

  • Page 27: Voltmeter/Ammeter Help Displays

    5-4. Voltmeter/Ammeter Help Displays HE.L P–1 HE.L P–2 HE.L P–3 HE.L P–4 HE.L P–5 HE.L P–6 HE.L P–7 HE.L P–8 All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 1 Display Indicates a malfunction in the pri- mary power circuit.

  • Page 28: Troubleshooting

    5-5. Troubleshooting Trouble No weld output; unit completely inop- Place line disconnect switch in On position (see Section 3-9). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-9). Check for proper input power connections (see Section 3-9). No weld output;...
  • Page 29 Notes OM-185 648 Page 25...

  • Page 30: Section 6 - Electrical Diagram

    SECTION 6 – ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Welding Power Source OM-185 648 Page 26...
  • Page 31 SD-185 518 OM-185 648 Page 27...

  • Page 32: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. 801 930-C Figure 7-1. Complete Assembly OM-185 648 Page 28...
  • Page 33 Item Dia. Part Mkgs....187 234 ..... . 195 585 .
  • Page 34 Item Dia. Part Mkgs....168 829 ....128 756 ..
  • Page 35 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local 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 36 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2001 Miller Electric Mfg. Co. 1/01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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