Miller Electric 456 CC Owner's Manual
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Miller Electric 456 CC Owner's Manual

Arc welding power source
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OM-188 422F
June 2001
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
Phoenix 456 CC/CV
(400 Volt Models)
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Electric 456 CC

  • Page 1 OM-188 422F June 2001 Processes Multiprocess Welding Description Arc Welding Power Source Phoenix 456 CC/CV (400 Volt Models) Visit our website at www.MillerWelds.com...
  • 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 Phoenix 456 CC/CV 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 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.

  • 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-188 422 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 Output Direct Current (DC) Constant Current Arc Force Rated No Load Voltage (Average) Hertz Pulsed Rated Maximum 1max 1eff Supply Current Panel Circuit Breaker Gas Tungsten Arc Welding Positive Constant Voltage Shielded Metal Arc Welding (SMAW) Primary Voltage Degree Of Protection...

  • Page 16: Manufacturer's Rating Label

    2-3. Manufacturer’s Rating Label S-184 765 / S-184 763 OM-188 422 Page 12...

  • Page 17: Section 3 - Installation

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

  • Page 18: Volt-Ampere Curve

    3-3. Volt-Ampere Curves 3-4. Dimensions And Weight Hole Layout Dimensions 14-21/64 in (363.9 mm) 20-3/4 in (527.1 mm) 23-27/64 in (594.9 mm) 24-31/32 in (634.2 mm) 12-3/8 in (314.3 mm) 9/32 in (7.1 mm) Dia. Weight 118 lb (53.5 kg) OM-188 422 Page 14 CV Modes CC Modes...

  • Page 19: Selecting A Location

    3-5. Selecting A Location Movement Location 18 in (460 mm) Tipping 18 in (460 mm) Y Do not move or operate unit where it could tip. Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit. Lifting Handles Use handles to lift unit.

  • Page 20: Weld Output Terminals And Selecting Cable Sizes

    3-6. 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 21: Remote 14 Receptacle Information

    3-7. Remote 14 Receptacle Information C L N Ref. ST-802 260 *The remaining sockets are not used. 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 22: 115 Volts Ac Duplex Receptacle

    3-8. 115 Volts AC Duplex Receptacle 3-9. 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 23: Connecting Input Power

    3-10. 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. =GND/PE Y Always connect grounding conductor first.

  • Page 24: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Front Panel Controls Power Switch The fan motor is thermostatically controlled and only runs when cooling is needed. Voltmeter (see Section 4-2) Ammeter (see Section 4-2) V/A (Voltage/Amperage) Adjust Control Voltage/Amperage Control Switch For front panel control, place switch in Panel position and use the V/A Adjust control.

  • Page 25: Meter Functions

    4-2. Meter Functions NOTE The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Lift-Arc Trigger Hold TIG (GTAW) TIG (GTAW) MIG (GMAW) Pulsed MIG (GMAW-P) Remote Control SMAW Panel Control SMAW Meter Reading At Idle Blank Preset Amps...

  • Page 26: Mode Switch Settings

    4-3. Mode Switch Settings NOTE The SMAW modes provide the Adaptive Hot Start increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start. Mode Lift-Arc Trigger Hold TIG (GTAW) TIG (GTAW) With HF Unit, Pulsing Device,...

  • Page 27: Lift-Arc Tig Procedure

    4-4. Lift-Arc TIG Procedure “Touch” Do NOT Strike Like A Match! 1 – 2 Seconds With Mode switch in the Lift-Arc TIG position, start an arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode.

  • Page 28: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Damaged Or Unreadable Labels 5-2. Blowing Out Inside Of Unit OM-188 422 Page 24 Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables Clean Tighten Weld Terminals 6 Months Blow Out Inside Maintain more often...

  • Page 29: 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 ter unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged be- fore working on unit.

  • Page 30: 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 OM-188 422 Page 26 All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.

  • Page 31: Troubleshooting

    5-5. Troubleshooting Trouble No weld output; unit completely inop- Place line disconnect switch in On position (see Section 3-10). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-10). Check for proper input power connections (see Section 3-10). No weld output;...

  • Page 32: Section 6 - Electrical Diagram

    SECTION 6 – ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Welding Power Source OM-188 422 Page 28...
  • Page 33 192 795 OM-188 422 Page 29...

  • Page 34: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. 802 261 Figure 7-1. Complete Assembly 802 261-C OM-188 422 Page 30...
  • Page 35 Item Dia. Part Mkgs....187 234 ..... . 195 585 .
  • Page 36 Item Dia. Part Mkgs....168 829 ..... . 174 992 .
  • Page 37 Notes OM-188 422 Page 33...
  • Page 38 Notes OM-188 422 Page 34...
  • Page 39 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 40: Owner's Record

    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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Phoenix 456 cvPhoenix 456 cc

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