Miller AlumaPower 350 MPa Owner's Manual
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Miller AlumaPower 350 MPa Owner's Manual

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AlumaPower 350 MPa
Auto-Line
OM-245 182A
2011−02
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Description
Arc Welding Power Source
™
™
CE
File: MIG (GMAW)

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  • Page 1 OM-245 182A 2011−02 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 _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Keep your head out of the fumes. Do not breathe the fumes. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

  • 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 For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • 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. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, 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- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-245 182 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Warning! Watch Out! There are possible Breathing welding fumes can be 3.3 Do not weld on drums or any closed hazards as shown by the symbols. hazardous to your health. containers. 2.1 Keep your head out of the fumes. Arc rays can burn eyes and injure Electric shock from welding electrode skin.
  • Page 16 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. Do not touch fully charged capacitors.

  • Page 17: Weee Label (For Products Sold Within The Eu)

    3-2. WEEE Label (For Products Sold Within The EU) Do not discard product (where ap- plicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility. Contact your local recycling office or your local distributor for further information.

  • Page 18: Section 4 − Introduction

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

  • Page 19: Duty Cycle And Overheating

    4-4. 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: Connecting 3-Phase Input Power

    5-5. Connecting 3-Phase Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Always connect green or green/ yellow conductor to supply grounding terminal first, and nev- = GND/PE Earth Ground er to a line terminal.

  • Page 23: Electrical Service Guide

    5-6. Electrical Service Guide 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 24: 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-G 2009−08 OM-245 182 Page 20...

  • Page 25: Remote 14 Receptacle Information

    5-8. 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 26: 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 27: 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 28 The AlumaPower 350 MPa and synergic feeders allow single knob control of the arc. As wirefeed speed is increased or decreased, the pulse parameters increase or decrease matching the power output to the wire speed.

  • Page 29: 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 Positive (+) Weld Output Terminal Gas Cylinder OM-245 182 Page 25...

  • Page 30: 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 31: Mig - Wire And Gas Selection Table

    7-3. MIG - Wire and Gas Selection Table WIRE TYPES GAS TYPES DEFAULT INDUCTANCE .035 AL4X (4000 Series) .040 AL4X (4000 Series) 3/64 AL4X (4000 Series) 1/16 AL4X (4000 Series) Aluminum ARGN (ARGON) .035 AL5X (5000 Series) .040 AL5X (5000 Series) 3/64 AL5X (5000 Series) 1/16 AL5X (5000 Series) Notes...

  • Page 32: 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 33: Pulsed Mig - Wire And Gas Selection Table

    7-5. Pulsed MIG - Wire and Gas Selection Table WIRE TYPES GAS TYPES .035 AL4X (4000 Series) .040 AL4X (4000 Series) ARGN (ARGON) 3/64 AL4X (4000 Series) 1/16 AL4X (4000 Series) Aluminum .035 AL5X (5000 Series) .040 AL5X (5000 Series) ARGN (ARGON) 3/64 AL5X (5000 Series) HE AR25 (HELIUM / ARGON)

  • Page 34: 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 35: 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 36: 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 37: Troubleshooting

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

  • Page 38: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram OM-245 182 Page 34...
  • Page 39 246 195-B OM-245 182 Page 35...

  • Page 40: Section −10 − Parts List

    SECTION −10 − PARTS LIST Ref. 245 184-A Figure 10-1. Parts Assembly OM-245 182 Page 36...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly ....221 786 Wrapper W/Insulators and Labels ....... . .
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly (Continued) ....218 566 Gasket, Inductor Mounting ........
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly (Continued) ....231 469 Nut, 500−28 .69Hex .28H Brs Conical Knurl ......
  • Page 44 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 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 MATERIAL THICKNESS GAUGE...
  • Page 47 Effective January 1, 2011 (Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • 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 2011 Miller Electric Mfg. Co. 2011−01...

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