Miller Continuum 500 Owner's Manual
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Miller Continuum 500 Owner's Manual

Arc welding power source
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www.MillerWelds.com
Continuum 350 And
Continuum 500
OM-257 798B
Processes
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Arc Welding Power Source
File: Advanced Manufacturing Systems
2015−02

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Summary of Contents for Miller Continuum 500

  • Page 1 OM-257 798B 2015−02 Processes Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Arc Welding Power Source Continuum 350 And Continuum 500 File: Advanced Manufacturing Systems 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 TABLE OF CONTENTS SECTION 8 − CONFIGURATION (IF EQUIPPED) ..........8-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 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 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 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 7: 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 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_2013−09 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 10 D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...

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

    LES BOUTEILLES peuvent exploser DES PIECES DE METAL ou DES si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
  • Page 12 LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- pements de radio−navigation et de com- D Utiliser des pochettes et des boîtes antista-...

  • Page 13: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.

  • Page 14: Section 3 − Definitions

    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 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 15 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 16: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Direct Current Alternating Amperage Voltage (DC) Current (AC) Output Input Remote Positive Negative Voltage Input Variable Protective Earth Arc Force Constant Voltage Inductance (Ground) Gas Metal Arc Increase Line Connection Arc Force...
  • Page 17 Notes OM-257 798 Page 13...

  • Page 18: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 19: Dimensions And Weight

    4-4. Dimensions And Weight Hole Layout Dimensions *27-3/16 in. 17-33/64 in. (445 mm) (691 mm) 28-3/32 in. (714 mm) 17-3/8 in. (441 mm) 26-11/64 in. (665 mm) 16-3/32 in. (409 mm) 24-57/64 in. (632 mm) 2-9/32 in. (58 mm) 15/32 in. (12 mm) 15/32 x 1 in.

  • Page 20: Duty Cycle And Overheating

    4-7. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 350 Model 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. Reduce amperage or duty cycle before welding.

  • Page 21: Section 5 − Installation

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

  • Page 22: Weld Output Terminals 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-K 2013−09 OM-257 798 Page 18...

  • Page 23: Connecting Weld Output Cables

    5-3. Connecting Weld Output Cables Turn off power before connecting to weld output tabs or receptacles. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Ensure all connections are tight. Tab Connection Do not place anything between weld cable terminal and output tab.

  • Page 24: Remote 10 Wire Feeder Control Receptacle Rc2 Information

    5-4. Remote 10 Wire Feeder Control Receptacle RC2 Information Socket Socket Information +50 Volts DC Common +50 Volts DC Common Voltage Sense +50 Volts DC Power +50 Volts DC Power ENET Rx − ENET Tx − Drain ENET Tx + ENET Rx + Ref.

  • Page 25: Supplementary Protector Cb1 And Optional Communication Panel

    5-6. Supplementary Protector CB1 And Optional Communication Panel Optional Ethernet Receptacle Used for connecting a computer di- rectly to the power source to ac- cess configuration web pages. Supplementory Protector CB1 CB1 protects the wirefeed motor from overload. If CB1 opens, the wirefeeder does not work.

  • Page 26: Electrical Service Guide

    5-8. Electrical Service Guide Elec Serv 2014−01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.
  • Page 27 Notes OM-257 798 Page 23...

  • Page 28: Connecting 3-Phase Input Power

    5-9. Connecting 3-Phase Input Power L1 (U) L2 (V) L3 (W) = GND/PE Earth Ground Input Power Contactor Connections Top View Of Unit Tools Needed: 3/8 in. 3/16 in. input5 2013−04 − 259 121-B OM-257 798 Page 24...
  • Page 29 5-9. Connecting 3-Phase Input Power (Continued) See rating label on unit and check input volt- Input Conductors L1, L2, L3 Installation must meet all National and age available at site. Local Codes − have only qualified per- Connect input conductors L1, L2, and L3 to sons make this installation.

  • Page 30: Section 6 − Recommended Setup Procedures

    SECTION 6 − RECOMMENDED SETUP PROCEDURES 6-1. Welding Circuit Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics. Welding Power Source Electrode Cable Feeder Cable Work Cable Standard Welding Circuit Volt Sense Lead Wire Feeder Workpiece In pulse welding applications using inverter...

  • Page 31: Arranging Welding Cables To Reduce Welding Circuit Inductance

    6-2. Arranging Welding Cables To Reduce Welding Circuit Inductance Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sense Lead Wire Feeder Workpiece The arrangement of the cables has an effect that is significant to the welding properties. As an example, Accupulse welding process can produce high welding circuit inductance depending on cable length and arrangement.

  • Page 32: Points Of Mechanics In Mig Welding

    6-3. 30 Points Of Mechanics In MIG Welding 30 Pts MIG − 2014-09 Primary Power Check primary power connection at line disconnect switch or receptacle and/or cord plug. Check primary power connection at welding power source. Secondary Power Check secondary weld output connections at welding power source. Inspect condition and routing of positive weld cable to wire drive motor.

  • Page 33: Arc Blow

    6-4. Arc Blow Arc blow is the deflection of the welding arc from its normal path due to magnetic forces. This condition is usually encountered in direct current welding of magnetic materials, such as iron and nickel. Arc blow can happen in alternating current welding under certain conditions, but these cases are rare and the intensity of the arc blow is always less severe.

  • Page 34: Basic Welding Troubleshooting

    6-5. Basic Welding Troubleshooting Listed below are some problems, causes and remedies related to welding operations; however, this list does not contain every possible condition that could be encountered in welding. Trouble Probable Cause Remedy No weld output; unit completely Line disconnect switch in Off position.
  • Page 35 Trouble Probable Cause Remedy Porosity in weld. Dirty base metal, heavy oxides, mill scale, oil, etc. Clean base metal by brushing, grinding or use chemical cleansing before welding. Regulator/flowmeter faulty. Adjust or replace regulator/flowmeter. Gas cylinder valve closed. Open gas cylinder valve. Gas regulator diaphragm defective.
  • Page 36 Trouble Probable Cause Remedy Wandering, hunting or erratic arc. Restriction in unspooler or drum adapter. Replace unspooler or repair restriction. Dirty or worn gun liner or inlet cable. Remove gun liner or inlet cable and clean or re- place. Sharp bends or kinks in gun cable or liner. Straighten gun cable and/or replace liner.

  • Page 37: Section 7 − Operation

    SECTION 7 − OPERATION 7-1. Operator Controls Power Switch Turns unit On or Off. Power On LED Power LED illuminates when unit is energized. Output On LED Output LED illuminates when weld output is energized. Over Temperature LED Over Temperature LED illuminates if unit overheats.

  • Page 38: Section 8 − Configuration (If Equipped)

    SECTION 8 − CONFIGURATION (IF EQUIPPED) 8-1. Accessing Configuration Web Pages To access the power source configuration webpages you will need the optional communication panel (See Section 5-6). Connect a PC directly to the jack on the communication panel with a CAT5 or CAT6 Ethernet cable. Enter the default IP address, 169.254.0.2, into a web browser and the welder configuration web pages will open to the Home screen.

  • Page 39: Setup Screen

    8-3. Setup Screen Information Bar negative weld leads, torch, and voltage feed- Auto Thread back (VFB) method that are selected. Edit but- Displays general information on power source, ton allows these parameters to be changed. Displays the Load Rate in inches per minute location, asset number, serial number, and dis- Jog Speed (IPM) and Torch Length (Inches) to determine...

  • Page 40: Data Management Screen

    8-5. Data Management Screen Software Information Error Log System Log Displays the software revision. Displays the last error experienced by the sys- Displays the last entry into the system log. Factory Reset button will take user to a Facto- tem. ry Reset screen.

  • Page 41: Section 9 − Maintenance & Troubleshooting

    SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent l Unreadable Labels ~ Weld Terminals nl Weld Cables...

  • Page 42: Error Code Troubleshooting Description And Tables

    9-3. Error Code Troubleshooting Description And Tables LED Display Message LCD Solution LCD Error Log LCD Display Message Message Type Message Message WELD WAIT ERROR Unit was not ready for a weld se- Press button to clear error Weld Wait Error quence ERR OVERTEMP ERROR...
  • Page 43 LED Display Message LCD Solution LCD Error Log LCD Display Message Message Type Message Message UNUSED 218 ERROR Unused Error #218 Cycle power on the power Unused Error #218 source ERR INPT PWR ERROR Must use three phase primary power Check primary connections Single Phase Error ERR INPT PWR...

  • Page 44: Troubleshooting

    LED Display Message LCD Solution LCD Error Log LCD Display Message Message Type Message Message ERR PWR SRC ERROR Boost current balance error Cycle power on the power Boost Current Balance Error source ERR PWR SRC ERROR Boost overcurrent error Cycle power on the power Boost Overcurrent Error source...
  • Page 45 Notes OM-257 798 Page 41...

  • Page 46: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Contiuum 350 Model (Page 1 of 2) OM-257 798 Page 42...
  • Page 47 264 238-B OM-257 798 Page 43...
  • Page 48 Figure 10-2. Circuit Diagram For Continuum 350 Model (Page 2 of 2) OM-257 798 Page 44...
  • Page 49 264 238-B OM-257 798 Page 45...
  • Page 50 Figure 10-3. Circuit Diagram For Contiuum 500 Model (Page 1 of 2) OM-257 798 Page 46...
  • Page 51 265 841-B OM-257 798 Page 47...
  • Page 52 Figure 10-4. Circuit Diagram For Continuum 500 Model (Page 2 of 2) OM-257 798 Page 48...
  • Page 53 265 841-B OM-257 798 Page 49...

  • Page 54: Section 11 − Parts List For 350 And 500 Models

    SECTION 11 − PARTS LIST FOR 350 AND 500 MODELS Figure 11-7 Figure 11-6 Figure 11-3 Figure 11-2 Figure 11-4 Figure 11-5 269 779-A Figure 11-1. Main Assembly OM-257 798 Page 50...
  • Page 55 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly Model Model ... . . +265236 Base ,Continuum .........
  • Page 56 Hardware is common and not available unless listed. 269 780-A Figure 11-2. Right-Hand Windtunnel w/Components Item Dia. Part Mkgs. Description Quantity Figure 11-2. Right-Hand Windtunnel w/Components (Figure 11-1, Item 12) Model Model ....265243 Windtunnel, Rh .
  • Page 57 Hardware is common and not available unless listed. 269 781-A Figure 11-3. Left-Hand Windtunnel w/Components Item Dia. Part Mkgs. Description Quantity Figure 11-3. Left-Hand Windtunnel w/Components (Figure 11-1, Item 13) Model Model ..L1-L4 ..252375 Inductor, Input .
  • Page 58 Hardware is common and not available unless listed. 269 782-A Figure 11-4. Fan Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-4. Fan Panel Assembly (Figure 11-1, Item 7) ....265241 Panel, Fan Motor .
  • Page 59 Hardware is common and not available unless listed. 269 783-A Figure 11-5. Front Panel Assembly Item Dia. Part Description Quantity Mkgs. Figure 11-5. Front Panel Assembly (Figure 11-1, Items 6, 8 and 10) ....252825 Bezel, Upper .
  • Page 60 Hardware is common and not available unless listed. 269 784-A Figure 11-6. Penthouse Assembly Item Dia. Part Description Quantity Mkgs. Figure 11-6. Penthouse Assembly (Figure 11-1, Item 11) ....245520 Bushing, Snap-in Nyl 1.062 Id X 1.500 Mtg Hole Cent .
  • Page 61 Hardware is common and not available unless listed. 269 785-A Figure 11-7. Rear Panel Assembly Item Dia. Part Description Quantity Mkgs. Figure 11-7. Rear Panel Assembly (Figure 11-1, Item 5) ... . . +265244 Panel, Rear .
  • Page 62 Notes OM-257 798 Page 58...
  • Page 63 Effective January 1, 2015 (Equipment with a serial number preface of MF 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 64 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 2015 Miller Electric Mfg. Co. 2015−01...

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Continuum 350 andContinuum 350

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