Miller AlumaPower 350 MPa Auto-Line CE Owner's Manual
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Miller AlumaPower 350 MPa Auto-Line CE Owner's Manual

Arc welding power source
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AlumaPower 350 MPa
Auto-Line
OM-245 182G
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Description
Arc Welding Power Source
™
™
CE
File: MIG (GMAW)
2013−02

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Summary of Contents for Miller AlumaPower 350 MPa Auto-Line CE

  • Page 1 OM-245 182G 2013−02 Processes MIG (GMAW) and Pulsed MIG (GMAW-P) Welding Description Arc Welding Power Source ™ AlumaPower 350 MPa ™ Auto-Line File: MIG (GMAW) Visit our website at 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 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 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 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 6 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging D Do not install unit near flammables.

  • Page 8: 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 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 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 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz D Fermer l’alimentation du gaz comprimé en cas sous haute pression. Si une bouteille est endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-245 182 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 16 Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Flying pieces of parts can cause injury. Always wear a face shield when servicing unit. Safe27 2012−05 Always wear long sleeves and button your collar when servicing unit.

  • Page 17: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Alternating Amperage Panel Voltage Current (AC) Output Circuit Breaker Remote Gas Tungsten Arc Negative Voltage Input Welding (GTAW) Direct Current Protective Earth Positive Inductance (DC) (Ground) Constant Current Constant Voltage Foot Control Line Connection Three Phase Static Frequency Con- Shielded Metal Arc Gas Metal Arc...

  • Page 18: Section 4 − Introduction

    SECTION 4 − INTRODUCTION 4-1. Specifications RMS Amps Input at Rated Load Output, 50/60 Hz 3-Phase at Input Voltage Range in Max. Open-Circuit NEMA Load Voltages and Class I Rated Output Power CV Mode Voltage Rating 230 V 400 V 460 V 350 A at 34 3-Phase...

  • Page 19: Duty Cycle And Overheating

    4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed and cooling fan runs. Wait fifteen min- utes for unit to cool. Reduce amper- age or voltage, or duty cycle before welding.

  • Page 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 21: Selecting A Location

    5-4. Selecting a Location Lifting Handles Use handles to lift unit. Hand Cart Use cart or similar device to move Movement unit. Line Disconnect Device Locate unit near correct input Do not move or operate unit power supply. where it could tip. Special installation may be required where gasoline or volatile liquids are present −...

  • Page 22: Weld Output Receptacles And 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-J 2011−07 OM-245 182 Page 18...

  • Page 23: Remote 14 Receptacle Information

    5-6. Remote 14 Receptacle Information Socket* Socket Information 24 volts AC. Protected by supplementary protect- 24 VOLTS AC or CB2. Contact closure to A completes 24 volts AC contactor control circuit. 115 volts AC. Protected by supplementary pro- 115 VOLTS AC tector CB1.

  • Page 24: Electrical Service Guide

    5-8. Electrical Service Guide Elec Serv 2011−08 NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.
  • Page 25 Notes OM-245 182 Page 21...

  • Page 26: Connecting 3-Phase Input Power

    5-9. Connecting 3-Phase Input Power = GND/PE Earth Ground Tools Needed: Input2 2012−05 − Ref. 803 766-C / Ref. 804 531-A OM-245 182 Page 22...
  • Page 27 5-9. Connecting 3-Phase Input Power (Continued) voltage available at site. This unit can be con- Input Conductors (L1, L2 And L3) Installation must meet all National and nected to any input power between 208 and Local Codes − have only qualified per- Disconnect Device Line Terminals 575 VAC without removing cover to relink the sons make this installation.

  • Page 28: Section 6 − General Operation

    SECTION 6 − GENERAL OPERATION 6-1. Front Panel Ref. 804 772-A / 245 172-A Right Display 10 Process Indicator Weld process operation sections de- scribe functionality of the identified items. 11 Arc Control Indicator The meters display the actual weld output values after arc initiation and remains dis- 12 Setup Button Remote 14 Receptacle...

  • Page 29: Configuration Option Menu

    6-2. Configuration Option Menu Ref. 245 172-A Left Display means to customize some machine features Configuration options are displayed in the Left for desired operation. Display. Settings are displayed in the Right Right Display Display. Settings can be changed by turning Adjustment Control To enter the Configuration Option Menu, hold the Adjust Control.
  • Page 30 Configuration Option Menu (Continued) Pulsed MIG Manual/Auto Control This option sets the Pulsed MIG control as manual (PULS MAN) or Auto (PULS AUTO) operation. When set to manual operation, the arc length setting on power source and wire AUTO PULS speed setting on wirefeeder need to be ad- justed independently to achieve the desired arc length.

  • Page 31: Section 7 − Gmaw/Gmaw-P

    SECTION 7 − GMAW/GMAW-P 7-1. Typical Connection For Remote Control Feeder GMAW/GMAW-P 805 058-A Negative (−) Weld Output Terminal Wire Feeder Turn off power before making connections. Ground Cable to Workpiece Gas Hose Remote 14-Receptacle Workpiece Gas Cylinder Positive (+) Weld Output Terminal OM-245 182 Page 27...

  • Page 32: Mig Welding Mode - Gmaw

    7-2. MIG Welding Mode - GMAW Ref. 245 172-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 33: Mig - Wire And Gas Selection Table

    7-3. MIG - Wire and Gas Selection Table WIRE TYPES* GAS TYPES 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) .040 (1.0) AL5X (5000 Series) 3/64 (1.2) AL5X (5000 Series) 1/16 (1.6) AL5X (5000 Series)

  • Page 34: Pulsed Mig Welding Mode - Gmaw-P Process

    7-4. Pulsed MIG Welding Mode - GMAW-P Process Ref. 245 172-A wire and gas being used. Refer to As wire feed speed increases, a higher arc Weld terminals energized Pulsed MIG − Wire and Gas Selection length setting is required to burn off the through the remote control in Table for available wires and gases additional wire.

  • Page 35: Pulsed Mig - Wire And Gas Selection Table

    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) Aluminum 3/64 (1.2) AL49 (4943) 1/16 (1.6) AL49 (4943)

  • Page 36: Remote Process Select

    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 37: Section 8 − Maintenance & Troubleshooting

    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 Repair Or Replace Cracked Cables And Cords Clean Tighten Weld...

  • Page 38: Help Displays

    8-3. Help Displays All directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. Help 1 Display HELP Indicates a malfunction in the primary power circuit. If this display is shown, contact a Fac- tory Authorized Service Agent.

  • Page 39: Troubleshooting

    8-4. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Section 5-9). erative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-9). Check for proper input power connections (see Section 5-9). No weld output;...

  • Page 40: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram OM-245 182 Page 36...
  • Page 41 256 237-A OM-245 182 Page 37...

  • Page 42: Section −10 − Parts List

    SECTION −10 − PARTS LIST 245 184-C Figure 10-1. Parts Assembly OM-245 182 Page 38...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly ....221 786 Wrapper W/Insulators and Labels ....... . .
  • Page 44 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly (Continued) ....083 147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High .
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly (Continued) ....218 041 Door, W/Quick Access Ball Fasteners ......
  • Page 46 Notes SOCKET/WRENCH SELECTION TABLE SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size U.S. Bolt Decimal Bolt Bolt Decimal Bolt Diameter Equivalent Diameter Equivalent 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm...
  • Page 47 Effective January 1, 2013 (Equipment with a serial number preface of MD 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 2013 Miller Electric Mfg. Co. 2013−01...

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