Miller Electric 400 User Manual

Miller
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Description
424E
1998
MIG
Flux
(GMAW)
Cored
Welding
(FCAW)
Welding
Arc
Welding
Wire
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Millermatic
Power
Source
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ThePower~f.~
TABLE
OF
CONTENTS
The
following
used
interchangeably
throughout
MIG=GMAW
this
term
manual:
is
SECTION
1-1.
1-2.
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.
2-11. 2-12.
2-13.
SECTION
3-1.
SECTION
4-1.
4-2. Circuit
4-3. 4-4.
4-5.
4-6.
SECTION SECTION
WAR
-
1
SAFETY
Symbol
Usage
Arc
Welding
Additional
Principal
EMF
Information
-
1
CONSIGNES
Safety
Signification
Dangers Dangers
et
relatifs
supplØmentaires
Ia
maintenance
Principales
Information
-
2
INSTALLATION
Specifications
Duty
Cycle
Volt-Ampere
Installing Installing
Setting
IRemote
Installing
Installing
Inductance Electrical
Selecting
Work
Welding
Gun
14
Gas
Wire
Service
a
Threading
-
3
OPERATION
Controls
-
4
MAINTENANCE
Routine
Unit
Maintenance
Breaker
Overload
Changing
Aligning
Drive
Troubleshooting
5-
ELECTRICAL
-
PARTS
6
RANTY
PRECAUTIONS
Hazards
Symbols
Standards
des
symboles
au
normes
sur
es
champs
And
Overheating
Curve
Clamp
Gun
Polarity
Receptacle
Supply
Spool
Selection
Guide
Location
Welding
CB1
Drive
Roll
Rolls
LIST
For
Installation,
DE
SECURITE
soudage
de
a
en
sØcuritØ
relation
Ølectromagnetiques
Not
(Gun
For
Wire
Type
and
Adjusting
and
Connecting
Wire
&TROUBLESHOOTINQ
Wire
Wire
Inlet
Guide
and
and
DIAGRA~L
-
READ
Operation,
-
LIRE
arc
avec
Included)
Hub
Input
Guide
BEFORE
USING
And
AVANT
Iinstallation,
Tension
Power
Maintenance
UTILISATION
le
fonctionnement
1 1 1
3 3
4
5
5 5
7
8 8 9 9
9 10 10
11
11
12
12 13
14 14
15 16
17 17
18 18 18 18 19 19
20
21
22
OM-189424E
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
_nd_5/97
1 1
4A
Marks
A
Means
ff7
1-2
The
A
to
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to
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follow
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repair
During
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circuits automatic metal installed
Do
Wear
.
Insulate
or
work
Do
there
Use
If
unit.
Disconnect
servicing
to
Properly
Owners
Always
power
in
grounded
When
conductor
Frequently replace
Turn
Do
Do
Synibol
Means
hazards
showninthe
a
special
Note~
Arc
symbols
call
attention
symbol,
avoid
a
summary
all
qualified
this
operation,
are
wire
touching
parts
or
improperly
touch
not
dry,
yourself
covers
or
ground.
not
use
is
a
AC
output
AC
output
OSHA
Manual
verify
cord
disconnect
making
cord
off
all
not
use
not
drape
Usage
Warning!
with
safety
not
safety
Welding
shown
to
watch
the
hazard.
of
Safety
Standards.
Safety
persons
unit.
keep
ELECTRICSHOCK
Touching
shocks
is
circuit
The
also
danger
this
29
install
input
live
when
welding,
the
grounded
electrical
live
hole-free
big
AC
from
enough
output
of
ONLY
is
required,
input
power
insulating
equipment.
CFR
191
and
and
the
supply
wire
ground
box
or
receptacle
input
-
first
double-check
inspect
input
immediately
equipment
worn,
damaged,
cables
Watch
this
procedure!
adjoining
message.
related.
Hazards
below
and
Standards
the
falling.
are
identify
and
out,
The
safety
the
more
should
everybody,
live
electrical
or
severe
electrically
power
power
wire
wire,
wire
welding
equipment
parts.
gloves
and
work
to
in
if
0.147
ground
national,
that
outlet.
ground
prevent
areas,
damp
required
remote
use
or
stop
Lockout/tagout
(see
this
state,
ground
is
properly
cord
connections,
connections.
cord
power
if
damaged
when
not
undersized,
over
your
Out!
There
The
possible
symbols.
used
throughout
possible
followthe
information
complete
listedinSection
install,
hazards.
related
safety
operate,
especially
kilL,
can
parts
burns.
The
live
circuit
is
reel,
are
any
for
electrode
whenever
and
In
on.
drive
roll
electrically
is
a
and
body
using
dry
physical
if
movement
the
welding
control
output
before
engine
input
Standards).
Safety
equipment
and
local
-
check
and
connected
is
connected
plug
attach
for
damage
-
bare
in
use.
or
poorly
body.
are
possible
hazards
this
When
instructions
below
given
information
Read
1
-4.
maintain,
children,
can
cause
and
the
output
machine
semiautomatic
housing,
live.
Incorrectly
hazard.
protection.
insulating
contact
with
is
confined,
process.
if
present
installing
according
power
according
codes.
be
that
sure
ground
to
a
bare
or
can
terminal
properly
grounding
to
proper
wiring
spliced
are
manual
you
and
and
away.
fatal
work
is
on.
internal
or
and
all
mats
the
or
on
to
input
wiring
kill.
cables.
or
its
This
ELECTRIC
Consult actionstoavoid
If
with
is
Do
or
Use
parts
Wear
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or
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contact
Do
single
SIGNIFICANT
input
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remove
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manufacturers
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person lower
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-
form
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weld
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symbols
earth
grounding
a
separate
touch
not
another
well-maintained
only
at
once.
a
safety
all
panels
work
worktable
work
with
not
connect
weld
power
Off
inverter,
touching
your
ventilate
inside,
welding
ventilation
the
and
inaconfined
an
nearby.
the
not
weld
highly
not
weld
area,
an
symbols
MOVING
and
related
the
hazards.
of
the
cable-do
electrode
Maintain
harness
and
with
near
as
clamp
metal
any
more
terminal.
DC
inverters.
on
disconnect
fromadifferent
covers
the
when
VOLTAGE
electrode
cable
output
according
parts.
any
FUMESAND
Welding
fumes
these
health.
of
out
head
the
fumes
is
use
poor,
Material
Safety
instructions
degreasers.
air-supplied
space
Welding
level
oxygen
safe.
air
is
locations
in
heat
The toxic
plated
the
on
area
and
and
irritating
coated
steel,
is
air-supplied
elements
these
means
Warning!
PARTS,
instructions
workpiece
not
use
you
in
are
if
equipment.
unit
according
if
working
securely
metal-to-metal
good
weld
as
connected
not
object.
than
one
input
instructions
to
GASES
produces
and
gases
fumes.
the
area
and/or
and
gases.
an
approved
Data
for
metals,
only
respirator.
fumes
and
causing
near
degreasing,
of
rays
gases.
metals,
the
unless
well
ventilated,
respirator.
can
give
Watch
and
HOT
PARTS
below
is
required,
work
contact
machine.
Repair
above
in
clamp
with
to
manual.
floor
place.
ground
the
or
replace
level.
contact
practical.
to
workpiece
electrodeorwork
exists
fumes
power,
can
Do
use
in
can
not
after
and
Maintenance
be
and
gases.
be
hazardous
breathe
exhaustatthe
air-supplied
Sheets
(MSDS5)
consumables,
ifitis
well
ventilated,
haveatrained
Always
injury
gases
or
can
death.
cleaning,orspraying
the
such
coating
The
arc
can
as
and
coatings
off
toxic
react
galvanized,
is
removed
if
necessary,
fumes
Out!
possible
hazards.
for
necessary
it
directly
work
cable.
or
work,
ground,
damaged
to
workpiece
to
prevent
cable
removal
discharge
Section
hazardous.
Breathing
to
the
fumes.
respirator.
and
coatings,
or
displace
Be
sure
with
vapors
lead,
from
and
any
if
welded.
to
any
input
your
arc
while
watch-
and
air
while
metals
of
to
the
the
to
or
the
OM-189
424
Page
1
Wear
a
welding
face
Z87.i
approved
protective
warn
protective
(leather
Accidental
sparks,
is
safe
before
yourself
weld
not
allflammables
is
not
alert
that
and
and
cause area
your
and
Wear
helmet.
Use
glare;
Wear
material
burns.
Protect
Do
Remove
this
Be
easilygothrough
Watch
for
Be
aware
can
cause
Do
weldonclosed
not
unless
they
Safety
Standards).
Connect
practical
unknown
Do
Remove
contact
Wear
shirt,
Remove
from
not
oil-free cuffless
your
work
to
paths
use
stick
tip
any
ARC
RAYS
Arc
rays
visible
and
that
can
weld.
helmetfitted
when
eyes
in
listed
Safety
safety
screens
others
not
clothing
and
WELDING
Welding
or
drums,
off
can
fly
hot
workpiece,
explosion,
possible,
fire,
that
fireonthe
prevent
when
contact
doing
and
where
flying
tightly
welding
small
and
keep
welding
are
properly
cabletothe
welding
and
causing
weldertothaw
electrode
not
protective
trousers,
combustibles,
before
person
FLYING
Welding,
cause
they
Wear shields
burn
can
from
the
welding
invisible
burn
eyes
with
and
a
(ultraviolet
proper
weldingorwatching
Standards).
barriers
watch
the
made
and
foot
can
cause
closed
can
the
welding
and
of
electrode
welding.
from
sparks
35ft
cover
hot
and
and
fire
a
extinguisher
a
ceiling,
side.
prepared
work
as
current
electric
frozen
from
holder
shoes,
such
doing
any
with
to
from
containers,
cause
hot
orfire.
flying
can
(10.7
them
such
according
pipes.
suchasleather
as
can
glasses
or
to
wool)
on
pipes,
from
overheating,
any
others
within
sparks
cracks
on
hidden
containers
in
use.
garments
high
METAL
chipping,
and
sparks
can
throw
off
approved
under
even
eyes
process
skin.
protect
arc.
and
Sparks
shadeoffilterto
side
shields
others
durable,
protection.
fire
or
to
them
The
arc.
equipment
metal
to
Check
sparks
strike
flammable
of
the
m)
with
approved
materials
openings
to
nearby.
floor,
bulkhead,
as
tanks,
to
the
to
close from
traveling
shock
and
oft
cut
or
and
a
cap.
butane
a
lighter
welding.
Injure
wire
brushing,
metal.Aswelds
flying
slag.
safety
glasses
welding
your
and
skin.
produce
(see
intense
infrared)
off
from
fly
protect
Z49.i
ANSI
under
flash
from
flame-resistant
explosion.
such
as
flying
cause
objects
be
hot
material.
welding
covers.
welding
or
F4.1
long,
hazards.
gloves,
or
matches,
eyes.
and
grinding
with
helmet.
tanks,
Sparks
sparks,
surethe
metal.
areas.
partition
or
pipes,
area
possibly
wire
heavy
blowup.
can
and
and
from
adjacent
drums,
AWS
welding
fire
welding
rays
the
your
and
fires
can
arc.
can
(see
as
cool,
side
OF
BUILDUP
Shut
off
Always approved
HOT
PARTS
not
Do
Allow
torch.
MAGNETIC
Pacemaker
Wearers
going
welding
NOISE
Noise
If
damage
can
from
hearing.
Wear
GAS
shielding
ventilate
air-supplied
can
hot
touch
cooling
period
FIELDS
wearers
should
near
arc
operations.
damage
some
approved
can
supply
gas
confined
respirator.
cause
parts
before
can
keep
consult
welding,
processes
ear
protection
injure
when
spaces
severe
bare
handed.
working
affect
away.
their
gouging,
hearing.
or
kilL
or
in
not
use.
or
use
burns~
on
or
gun
pacemakers.
before
doctor
or
spot
level
can
is
equipment
if
noise
high.
CYLINDERS
Shielding
pressure.
Since
gas
process,
Protect
mechanical
Install
at
I
I
S
support
Keep
Never
Never
Never
Use
fittings
associated
Turn
Keep
use
Read
associated Standards.
compressed
shocks,
cylinders
or
cylinder
cylinders
a
drape
allow
a
weld
on
correct
only
designed
parts
face
away
protective
connected
or
follow
and
equipment,
slag,
in
an
upright
rack
from
away
welding
welding
a
pressurized
shielding
for
the
in
good
from
valve
in
cap
for
instructions
can
explode
cylinders
gas
If
damaged,acylinder
are
cylinders
be
sure
gas
open
to
prevent
any
torch
electrodetotouch
gas
specific
condition.
outlet
place
use.
and
CGA
normally
treat
to
cylinders
flames,
position
falling
welding
over
a
gas
cylinder
cylinders,
application;
when
valve
over
on
compressed
publication
them
by
or
-
except
contain
if
damaged;
gas
can
of
part
carefully.
from
excessive
and
sparks,
or
tipping.
electrical
to
securing
other
cylinder.
cylinder.
any
explosion
regulators,
maintain
opening
cylinder
when
gas
P-i
listed
under
explode.
the
welding
arcs.
a
stationary
circuits.
will
result.
hoses,
them
valve.
cylinder
cylinders,
in
Safety
high
heat,
and
and
is
in
OM-189
424
Page
2
:1-3.
Additional
Symbols
For
Installation,
Operation,
And
Maintenance
Do
not
is
properly
FIRE
overload
sized,
FALLiNG
OVERUSE
STATIC
Do combustible
Do
building
rated,
Use
gear,
Use
support
If
using
long
unit.
Allow
Reduce
starting
Do
OR
EXPLOSION
install
not
install
not
wiring
and
UNIT
lifting
eye
cylinders,
gas
equipment
unit.
lift
forks
enough
an
cooling
current
to
weld
block
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or
place
surfaces.
unit
near
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be
sure
protected
can
lift
to
or
of
adequate
to
move
to
extend
cause
period;
reduce
or
again.
filter
airflowtounit.
or
can
damage
hazard.
unit
on,
flammables.
power
handle
to
cause
unit
only,
other
any
capacityto
be
unit,
beyond
OVERHEATING
follow
rated
duty
or
over,
supply
system
this
unit.
injury.
NOT
running
accessories.
forks
sure
opposite
duty
cycle
PC
boards~
near
lift
and
are
of
side
cycle.
before
The
promptly
installation.
If
notified
equipment
Have
Keep keep
shielding
MOV!NGPARTS
Keep
Keep
closed
RADIATION
H.F.
High-frequency
navigation,
communications
Have electronic
is
user
responsible
correct
any
FCC
the
by
at
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424
Page
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Page
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SECTION
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OM-189
424
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OM-189
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Page
7
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