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Summary of Contents for Miller Electric Millermatic 400
- Page 1 Millermatic 400 Visit webs~te Www~MllI~rWeIds.com Miller The Power OJIB& OWNERS MANUAL OM-iBO 424E August 1998 Processes (GMAW) Welding Flux Cored (FCAW) Welding Description Power Source Welding and Wire Feeder...
- Page 2 U.S.A. will then registered to ibe Iso 9001 quality you may need System Standard. service information also Miller Electric manufactures full of welders and welding related equipment. information other quality your local Miller distributor products, contact...
- Page 3 following term SECTION used interchangeably 1-1. throughout this manual: 1-2. MIG=GMAW 1-3. 1-4. 1-5. SECTION 1-1. 1-2. 1-3. 1-4. 1-5. SECTION 2-1. 2-2. 2-3. 2-4. 2-5, 2-6. 2-7. 2-8. 2-9. 2-10. Inductance Selection 2-11. Electrical Service Guide 2-12. 2-13. SECTION 3 3-1.
- Page 5 SECTION SAFETY PRECAUTIONS Synibol Usage Means Watch Out! Warning! hazards with this procedure! shown in the adjoining symbols. Marks special safety message. Means Note~ safety related. Welding Hazards symbols shown below used throughout to call attention identify possible seethe watch and followthe related symbol, out,...
- Page 6 Connect work cable the work close practical welding from prevent current unknown electric shock and fire hazards. paths causing welder thaw frozen pipes. Remove stick electrode from holder when contact use. Wear oil-free protective garments such shirt, cuffless trousers, high...
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Page 7: Principal Safety
Additional Symbols :1-3. FIRE OR EXPLOSION install place combustible surfaces. install unit near Do not overload building wiring sure properly sized, rated, protected FALLiNG UNIT can cause lifting lift unit cylinders, gear, gas equipment adequate capacityto unit. support lift forks using move long enough... -
Page 8: Emf Information
EMF Information 1-5.. Considerations About Welding And The Effects Of Low Electric And Magnetic Fields it flows Welding current, through welding magnetic fields. There has been and still is some fields. However, after examining than 500 studies more years of research, special blue ribbon... - Page 9 SECTION CONSIGNES Signification symboles Signifie Mise garde! Soyez vigilant! prØsente risques danger! symboles adjacents Identifie sØcuritØ particulier. message Signifie NOTA nest pas re/at/f a Ia sØcuritØ. Dangers relatifs soudage prØsentØs ci-aprŁs symboles sont utilisØs present manuel pour attirer votre attention et identifier les risques danger.
- Page 10 LES RAVONS DE LARC brlures voquer peau. de larc rayonnement genere des rayons visibles (ultraviolets infrarouges) susceptibles bthlures Ia peau. Des Øtincelles dans yeux pendant soudage. Porter casque de soudage muni dun Øcran de filtre proteger votre visage pendant yeux Z87.
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Page 11: Section 2 Installation
1 -3. Dangers supplØmentaires Ia maintenance Risque DJNCENDIE DEXPLOSION. Ne pas placer lappareil proximitØ de surfaces infilammables. pas installer lappareil proximite produits NepassurchargerlinstallationØlectrique tation est correctement dimensionnØ protØgØ lappareil service. CHUTE LAPPAREIL blesser. Utiliser lanrieau de levage uniquement lever lappareil, NON PAS les de gaz tout autre... - Page 12 1-4. Principales normes Safety ANSI Z49. Welding Cutting, norme 550 NW. Miami FL 33126 ding Society, Lejeune Safetyand Health Sandards, OSHA 29 CFR Documents, U.S. Government Printing 20402. Safe Recommended Practice for the Preparation of Containers That Have Held Hazardous ting AWS F4.1 de American...
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Page 13: Specifications
(0.6 2-2. Duty Cycle Overheating Overheating INSTALLATION Ra ted Amps Input Max. Open Circuit Voltage 230 V 400 V 44.4 25.5 Wire Feed Dimensions Speed Flux Cored 50-670 1PM H: 37 in W: 19 in (1.2-1.7 m/min) .030 1/16 (0.8... -
Page 14: Volt-Ampere Curve
2-3. Volt-Ampere Curve 2-4. Installing Work Clamp OM-189 Page ~L5J 3~C) EL AIVEEFES Normal Volt-Ampere volt-ampere curves minimum and normal voltage amperage of the pabilities welding Curves of other source. fall between the curves Overload Volt-Ampere Curves When unit is used beyond ity, circuitry the overload... -
Page 15: Installing Welding
2-5. Installing Welding 2-6. Setting Polarity To Positive Reverse Lead Connections Negative (DCEN) (FCAW Process). Becomes ~=:~ 3/4,11/l6in (Gun Included) For Wire Type Shown Shipped Set For Electrode Positive For Solid Steel Or (DCEP) Aluminum Wires (GMAW Process). Wire Drive Assembly Lead Terminal... -
Page 16: Gas Supply
2-7. Remote Receptacle i~:i Ref. ST-152 973-A *The remaining sockets used. 2-8. Installing Supply OM-189 Page Socket* REMOTE 14 24 volts OWPUT Contact closure (cONTACTOR) circuit. Circuit Argon Socket Information Protected circuit breaker CB2. to A 24 volts completes contactor for 24 and 115 volts circuits. -
Page 17: Installing Wire Spool And Adjusting Hub Tension
2-9. Installing Wire Spool Adjusting Hub Tension OM-189 424 Page... -
Page 18: Electrical Service Guide
2-10. Inductance Selection Tools Needed: 3/8,7/l6in ~ZJiJ Weld Bead Using Connection With 17 Electrical Service Guide 2-11. Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Amperes Conductor Size In AWG/KcmiI Input Max Recommended Conductor Input Conductor Size In Grounding... -
Page 19: Connecting Input
Remove wrapper. Jumper Link Label Connecting Input Power Tools Needed: ~ 3/8 ===z c:I::::::1:=:=~lJ GND/PE Connect First 400 VOLTS 000000 Links Jumper Move jumper links to match Reinstall wrapper. A Special installation may volatile liquids CEC Section 20. GND/PE... - Page 20 Wire 2-13. Threadrng Welding Open assembly. pressure Close and tighten pressure assembly, and let of wire. Press gun trigger until wire of gun. Reinstall comes contact and nozzle OM-189 Page Pull and hold wire; cut off end. Remove nozzle and contact 1111 Feed wire check drive roll...
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Page 21: Section 3 Operation
SECTION OPERATION Controls 3-1. OM-189 424 Page... -
Page 22: Routine Maintenance
SECTION MAINTENANCE 4-1. Routine Maintenance Circuit Breaker CB1 4-2. Overload 4-3. Unit If unit is used beyond capacity (excessive this condition. trigger to reset OM-189 Page &TROUBLESHOOTING Disconnect power before maintaining, wire feeds but is not wire feed, shorted output, etc.), Maintain often... - Page 23 Drive Roll and Wire Inlet Guide 4-4. Changing Tools Needed: 5/64 7/l6in Drive Rolls and Wire Guide 4-5. Aligning Tools Needed: Correct Incorrect NOTE: Drive rolls and inlet wire included. guide Table 6-1 for informa ordering tion. Securing Screw Inlet Wire Guide Slide Loosen close to...
- Page 24 Troubleshooting 4-6. Trouble Remedy wire does feed. No weld output; Replace building Reset circuit breaker Secure gun Have Have No weld wire feeds. Thermostat TP1 open output; (see Connect work Replace An overload condition occurred. Release Have Connect unit Low weld output.
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Page 25: Electrical Diagram
SECTION ELECTRICAL DIAGRAM SD-I Circuit Figure 5-1. Diagram OM-189 Page... -
Page 26: Section 6 Parts List
SECTION 6- PARTS LIST OM-1 89424 Page 6-1. Main Figure Assembly Hardware is common available unless listed. ST-802... - Page 27 Item Dia. Part Mkgs. Figure HOUSING RECEPTACLE & SOCKETS PLG8 008072 Fig6-2 BAFFLE, ...3...T1 TRANSFORMER, ...189414 THERMOSTAT, ..163 266 PANEL, Fig6-6 146165 PANEL, 089899 LATCH, +146167 PANEL, 134464 LABEL, WRAPPER +170513 187804 CABLE, 185541 ...BASE 186758 ...WHEEL 052692 AXLE, SR1...185555 RECTIFIER, ...14...
- Page 28 Hardware is common available unless listed. OM-1 89 424 Page Center w/Components Figure 6-2. Baffle, ST-8O1 952-A...
- Page 29 Item Dia. Part Mkgs. Figure RING, .058427 NUT, 085 980 WASHER, .605941 186437 SPRING, 057 971 WASHER, SPRING, 057 745 186435 HUB, 186436 WASHER, 177307 REEL, support BAFFLE, .188710 184965 CAPACITOR ASSEMBLY 186998 082 902 185643 083 147 14... 184584 187752 15...
- Page 30 Dia. Part Item Mkgs. +188 189 350 R2,3 035897.. 185 890 185896.. C13-15 148 240 186473.. 128 756.. 048 282.. 143 976.. 186470.. 186 472 12... 157 958 097 924 Hardware is common not available unless listed. To maintain the factory original performance Replacement Parts.
- Page 31 Item Dia. Part Mkgs. Figure 602 009 SCREW, 172 075 CARRIER, 166072 SPACER, 010224...PIN,springCS.187x1.000 HOUSING, adapter 182 788 085 242 FASTENER, pinned 085 244 WASHER, SPRING, 010 231 085 243 KNOB, 166 071 LEVER, 079634 PIN, 151 828... PIN, 173 616 COVER, 173 435 MOTOR,...
- Page 32 NoteL~ Base selection of drive rolls upon V-Grooved U-Grooved rolls for soft and soft shelled cored wires. U-Cogged V-Knurled rolls for hard shelled cored wires. Drive roll with U-Grooved). Wire Diameter Decimal Fraction .023/.025 .023/.025 .030 in. .030 in. .035 in. .035 in.
- Page 35 : p S t s c a n b e i n y o u r Warranty Questions2 Call 1-800-4-A-MILLER ioryoir Scat:, Miller distributor. ~Your distributor also gives ::.senn~ always:get fast: reIi~le resportse need; Most replacement hahds. in 24 Pours, :~Uppofl.
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Page 36: Owner's Record
Owners Record Please complete and retain with your Model Name Purchase Date (Date Distributor Address City State Resources Available Always provide Model Name and Serial/Style Contact your Distributor for: To locate distributor nearest you call 1-800-4-A-Miller. Contact DeliveriuD Carrier br: filing For assistance in settling...
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