Miller AlumaPower 450 MPa Owner's Manual
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Miller AlumaPower 450 MPa Owner's Manual

Arc welding power source. 400 volt model
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AlumaPower 450 MPa
(400 Volt Model) CE
OM-257219R
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Description
Arc Welding Power Source
™
File: MIG (GMAW)
2016−10

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  • Page 1 OM-257219R 2016−10 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Description Arc Welding Power Source ™ AlumaPower 450 MPa (400 Volt Model) CE File: MIG (GMAW) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
  • Page 3 TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING ......... 8-1.

  • Page 5: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
  • Page 6 XMT 450 CC/CV 400V W/AUX POWER (CE) 907525 XMT 450 MPA 400V (CE) 907468 INVISION 450 MPA 400V W/AUX POWER (CE) 907524 ALUMAPOWER 450 MPA 400V W/AUX POWER (CE) 907526 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 8 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 14: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 15: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste.
  • Page 16 A complete Parts List is available at www.MillerWelds.com Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Flying pieces of parts can cause injury.
  • Page 17 A complete Parts List is available at www.MillerWelds.com Environmental Protection Use Period (China) Safe123 2016−06 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Safe38 2012−05 Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk...

  • Page 18: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Gas Tungsten Arc Amperage Welding Alternating Current (AC) Positive Voltage Shielded Metal Arc Welding (SMAW) Voltage Input Primary Voltage Protective Earth Degree Of (Ground) Protection Lift-Arc Trigger Line Connection Hold Operation (GTAW)

  • Page 19: Section 4 − Specifications

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Features And Benefits LVCt Line Voltage Compensation is circuitry that keeps the power source output constant regardless of input pow- er fluctuation. Wind Tunnel Technologyt circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments.

  • Page 20: Environmental Specifications

    A complete Parts List is available at www.MillerWelds.com 4-6. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered. IP23 2014−06 B.

  • Page 21: Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 22: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 23: Selecting Cable Sizes

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-L 2015−02 5-3. Weld Output Terminals Turn off power before connecting to weld output terminals.

  • Page 24: Connecting Weld Output Cables

    A complete Parts List is available at www.MillerWelds.com 5-4. Connecting Weld Output Cables Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) Incorrect Installation 803 778-B Weld Output Terminal output terminal and secure with nut so that Turn off power before connecting to weld cable terminal is tight against copper Supplied Weld Output Terminal Nut...

  • Page 25: Volts Ac Duplex Receptacle And Supplementary Protectors

    A complete Parts List is available at www.MillerWelds.com 5-6. 115 Volts AC Duplex Receptacle And Supplementary Protectors 115 V 7 Amp AC Receptacle Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects duplex receptacle. CB2 protects 24 volts AC portion of Remote receptacle from...

  • Page 26: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 5-7. Electrical Service Guide Elec Serv 2014−01 NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera- tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
  • Page 27 A complete Parts List is available at www.MillerWelds.com Notes OM-257219 Page 21...

  • Page 28: Connecting Input Power

    A complete Parts List is available at www.MillerWelds.com 5-8. Connecting Input Power = GND/PE Earth Ground Tools Needed: 5/16 in. Input5 2013−04 / Ref. 803 766-C / 257 348-A OM-257219 Page 22...
  • Page 29 A complete Parts List is available at www.MillerWelds.com 5-8. Connecting Input Power (Continued) Supplied Cord) Connect input conductors L1, L2, and L3 to Turn Off welding power source, and welding power source line terminals. check voltage on input capacitors Select size and length of conductors using according to Section 8-3 before Section 5-2.

  • Page 30: Section 6 − General Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − GENERAL OPERATION 6-1. Front Panel 252 024-A / 256 367-A played for approximately three seconds 11 Arc Control Indicator Weld process operation sections de- after the arc is broken. scribe functionality of the identified items.

  • Page 31: Configuration Option Menu

    A complete Parts List is available at www.MillerWelds.com 6-2. Configuration Option Menu 256 367-A Remote 14 Receptacle The Configuration Option Menu provides a momentarily. means to customize some machine features Left Display Configuration options are displayed in the Left for desired operation. Right Display Display.
  • Page 32 The AlumaPower 450 MPa and synergic feeders allow single knob control of the arc. As wirefeed speed is increased or decreased, the pulse param- eters increase or decrease matching the power output to the wire speed.

  • Page 33: Section 7 − Gmaw/Gmaw-P/Fcaw Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − GMAW/GMAW-P/FCAW OPERATION 7-1. Typical Connection For Remote Control Feeder GMAW/GMAW-P Process Ref. 277770-A Ground Cable to Workpiece Gas Hose Turn off power before making connections. Workpiece Gas Cylinder Remote 14-Receptacle Positive (+) Weld Output Terminal Use of shielding gas is dependant on Wire Negative (−) Weld Output Terminal...

  • Page 34: Mig Welding Mode - Gmaw Process

    A complete Parts List is available at www.MillerWelds.com 7-2. MIG Welding Mode - GMAW Process 25. 0 256 367-A Press the Setup Button again. Wire/Gas In- Pressing the Setup Button allows adjust- Weld terminals energized dicator is lit. The active gas type will appear ment of Arc Control, Wire Type, Gas Type through the remote control in MIG in the Left and Right Display.

  • Page 35: Mig - Wire And Gas Selection Table

    A complete Parts List is available at www.MillerWelds.com 7-3. MIG - Wire and Gas Selection Table WIRE TYPES* GAS TYPE DEFAULT INDUCTANCE .035 (0.9) AL4X (4000 Series) .040 (1.0) AL4X (4000 Series) 3/64 (1.2) AL4X (4000 Series) 1/16 (1.6) AL4X (4000 Series) Aluminum ARGN (ARGON) .035 (0.9) AL5X (5000 Series)

  • Page 36: Pulsed Mig Welding Mode - Gmaw-P Process

    A complete Parts List is available at www.MillerWelds.com 7-4. Pulsed MIG Welding Mode - GMAW-P Process 25. 0 Ref. 256 367-A Pulsed MIG − Wire and Gas Selection additional wire. The arc length setting ap- Weld terminals energized Table for available wires and gases pears in the Left Display when the Arc through the remote control in (see Section 7-5).

  • Page 37: Pulsed Mig - Wire And Gas Selection Table

    A complete Parts List is available at www.MillerWelds.com 7-5. Pulsed MIG - Wire and Gas Selection Table WIRE TYPES* GAS TYPES .035 (0.9) AL4X (4000 Series) .040 (1.0) AL4X (4000 Series) 3/64 (1.2) AL4X (4000 Series) 1/16 (1.6) AL4X (4000 Series) ARGN (ARGON) .035 (0.9) AL49 (4943) .040 (1.0) AL49 (4943)

  • Page 38: Remote Process Select

    A complete Parts List is available at www.MillerWelds.com 7-6. Remote Process Select This power source can be used with wire feeders that support Remote Process Se- lect. This feature allows the operator to switch the active welding process between MIG and Pulsed MIG at the wire feeder. To determine if the welding system is Remote Process Select capable, connect the wire feeder to the power source and review the...

  • Page 39: Section 8 − Maintenance & Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Repair Or Replace Replace Cracked Replace Damaged Or Torch Body Cracked Unreadable Cables Labels...

  • Page 40: Removing Case And Measuring Input Capacitor Voltage In 400 Vac Models

    A complete Parts List is available at www.MillerWelds.com 8-3. Removing Case and Measuring Input Capacitor Voltage In 400 VAC Models Turn Off welding power source, and disconnect in- put power. Significant DC voltage can remain on capacitors after Typical Bleeder Resistor unit is Off.

  • Page 41: Help Displays

    A complete Parts List is available at www.MillerWelds.com 8-4. Help Displays All directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. HE.L Help 1 Display Indicates a malfunction in the primary power circuit.

  • Page 42: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram OM-257219 Page 36...
  • Page 43 253 463-C OM-257219 Page 37...
  • Page 44 Notes...
  • Page 45 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 46 Notes...
  • Page 47 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 48 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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