Miller Invision 456MP Owner's Manual
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Miller Invision 456MP Owner's Manual

Miller Invision 456MP Owner's Manual

(230/460 and 575 volt models)
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Invision 456MP
(230/460 And 575 Volt Models)
OM-193 267J
August 2003
Processes
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
Description
R

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  • Page 1 OM-193 267J August 2003 Processes Processes MIG (GMAW) and Pulsed MIG (GMAW-P) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding Description Invision 456MP (230/460 And 575 Volt Models) 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 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • 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 cause injury. 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: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org).

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 7/02 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org).

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Maximum Amperes Input At Rated Open- Load Output 60 Hz, Input Rated Welding Voltage Circuit Three-Phase Power Power Output Output Range Range Voltage Voltage 230 V 460 V 575 V 230/460 230/460 450 A @ 38 Volts DC, Three 50.8 27.8...

  • Page 14: Volt-Ampere Curves

    3-3. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and A. CV Mode amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. B. CC Mode 181 562 / 216 408-A 3-4. Dimensions and Weight Hole Layout Dimensions 14-21/64 in (363.9 mm) 20-3/4 in (527.1 mm)

  • Page 15: Selecting A Location

    3-5. Selecting a Location Y Do not move or operate Movement Tipping unit where it could tip. Lifting Forks Location Use lifting forks to move unit. Extend forks beyond opposite side of unit. Lifting Handles Use handles to lift unit. Hand Cart Use cart or similar device to move unit.

  • Page 16: Remote 14 Receptacle Information

    3-7. Remote 14 Receptacle Information Socket* Socket Information 24 volts ac. Protected by circuit breaker CB2. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volts ac con- tactor control circuit. Ref. 802 314 115 volts ac. Protected by circuit breaker CB1. 115 VOLTS AC 115 VOLTS AC C L N...

  • Page 17: 115 Volts Ac Duplex Receptacle And Circuit Breakers

    3-8. 115 Volts AC Duplex Receptacle and Circuit Breakers 115 V 10 A AC Receptacle Power is shared between duplex receptacle and Remote 14 recep- tacle (see Section 3-7). Circuit Breaker CB1 Circuit Breaker CB2 CB1 protects duplex receptacle and 115 volts ac portion of Remote 14 receptacle from overload.

  • Page 18: Selecting Input Voltage

    3-10. Selecting Input Voltage Y Turn Off welding power source, disconnect input power, and check voltage on input capacitors according Section before proceeding. Be sure to reinstall all four screws Check input voltage available at securing relinking board in place. site.

  • Page 19: Connecting Input Power

    3-11. Connecting Input Power Y Turn Off welding power source, and check voltage on input capacitors according Section before proceeding. Strain Relief Connector Clamp Obtain and install proper connector. Input And Grounding Conductors Contactor W1 Select size and length using Sec- tion 3-9.

  • Page 20: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Front Panel Controls Power Switch amperage. Increment Push Button (see Section 4-4) The fan motor is thermostatically Trim Indicator Light Decrement Push Button (see Section controlled and only runs when cooling is 4-4) needed. Lights when display beneath is indicating trim.

  • Page 21: Meter Functions

    4-2. Meter Functions NOTE The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Meter Reading While Welding 24.5 24.5 Preset Volts Blank Actual Volts Actual Amps Trim Pulsed 24.5 Blank...

  • Page 22: Example Displays

    4-3. Example Displays Values shown are hypothetical. The “A” (Amperage) and “Trim” lights illuminate as shown. Amperage preset display for Stick welding mode. Voltage preset display for MIG welding mode. Display while welding. Preset trim display for Pulse welding mode. Preset pulses per second (PPS) display for Manual Pulse welding mode.

  • Page 23: Synergic Controls And Overview

    4-4. Synergic Controls and Overview Controls Display Parameter Select Push Button Press button to move > on display. The parameter indicated by > is selected. Increment Push Button Press increment button to increase selected parameter. Decrement Push Button Press decrement button decrease selected parameter.

  • Page 24: Initial Display, Manual Pulse Mig Mode, Mig Mode, And Stick Mode

    4-5. Initial Display, Manual Pulse MIG Mode, MIG Mode, and Stick Mode Software Program Number When power is applied, initial dis- play with software number appears momentarily, and then last program to be viewed before control was shut down appears. I N V I S I O N 4 5 6 M P Manual Pulse MIG Mode...

  • Page 25: Setup Screens

    4-6. Setup Screens To access Setup screens: turn welding power source Off, press and hold Select push button, turn unit On, and hold push button down until initial screen leaves. To exit Setup screens, turn welding power source Off and then On again.

  • Page 26: Choosing Pulse Programs And Setting Parameters

    4-7. Choosing Pulse Programs and Setting Parameters Choosing Pulse Program: Pulse programs are pre-written and cannot be changed by the user. See Section 5 for program parameters and recommended gas mixtures. Choose program depending on the type and size of wire, and type of shielding gas used.

  • Page 27: How Manual Pulsed Mig Waveform Components Affect Arc And Burn-Off Rate

    4-8. How Manual Pulsed MIG Waveform Components Affect Arc and Burn-Off Rate Return To Table Of Contents OM-193 267 Page 23...

  • Page 28: Section 5 − Programs

    SECTION 5 − PROGRAMS NOTE Section 5-1 provides basic information on each of the fifteen programs in the unit’s memory. See Section 5-2 for more detailed information on each of the programs. NOTE Synergic Information: The manufacturer makes no warranties, express or implied, that welds made using the synergic parameters of this equipment will meet the requirements of the application.

  • Page 29: Programs

    5-2. Programs Program 1 −− .035 ER70S−3 Mild Steel −− Recommended Gases: Argon/CO Gases: Argon/CO mixes up to 10% CO Argon/O mixes up to 5% O Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps 1.48 1.62 1.75 1.87 1.95 1.98 2.10...
  • Page 30 Program 3 −− .052 ER70S−3 Mild Steel −− Recommended Gases: Argon/CO Gases: Argon/CO mixes up to 10% CO Argon/O mixes up to 5% O Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps 2.30 2.43 2.58 2.70 2.80 2.90 3.00 3.10 3.15...
  • Page 31 Program 6 −− .045 309L Stainless Steel −− Recommended Gases: 98 Argon/2 CO Alternative Gases: Argon/CO mixes up to 10% CO Argon/O mixes up to 5% O Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps 1.50 1.65 1.75 1.85 1.97 2.09...
  • Page 32 Program 9 −− 1/16 .062 Aluminum 4043 −− Argon Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps 2.15 2.40 2.60 2.89 3.15 3.35 3.55 3.70 3.90 4.05 4.18 Program 10 −− .035 Aluminum 5356 −− Argon Trim Peak Amp Background Amp Freq.
  • Page 33 Program 12 −− .062 Aluminum 5356 −− Argon Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps 2.25 2.38 2.55 2.69 2.80 2.91 3.04 3.19 3.34 3.42 3.50 Program 13 −− .035 Nickel −− 75 Argon/25 Helium Trim Peak Amp Background Amp Freq.
  • Page 34 Program 15 −− .035 Silicon Bronze −− Argon Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 Program 16 −− .045 Metal Core −− Recommended Gases: Argon/CO Gases: Argon/CO mixes up to 20% CO Trim Peak Amp...
  • Page 35 Program 18 −− .062 Metal Core −− Recommended Gases: Argon/CO Gases: Argon/CO mixes up to 20% CO Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps 2.10 2.30 2.40 2.50 2.60 2.75 2.90 3.05 3.20 3.35 3.50 Return To Table Of Contents OM-193 267 Page 31...

  • Page 36: Section 6 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 3 Months Replace Repair or Replace damaged or replace cracked unreadable cracked torch body. label. cables. Repair or replace cracked cables and cords.

  • Page 37: Removing Right Side Panel And Measuring Input Capacitor Voltage In 230/460 Volt Models

    6-3. Removing Right Side Panel and Measuring Input Capacitor Voltage in 230/460 Volt Models Turn Off welding power source, and disconnect input power. Y Significant DC voltage can remain on capacitors af- Right Side Panel ter unit is Off. Always check the voltage as shown To remove panel, remove screws to be sure the input capacitors have discharged be- securing panel to unit.

  • Page 38: Removing Right Side Panel And Measuring Input Capacitor Voltage In

    6-4. Removing Right Side Panel and Measuring Input Capacitor Voltage in 575 Volt Models Turn Off welding power source, and Y Significant DC voltage can remain on capacitors af- disconnect input power. ter unit is Off. Always check the voltage as shown Right Side Panel to be sure the input capacitors have discharged be- fore working on unit.

  • Page 39: Voltmeter/Ammeter Help Displays

    6-5. Voltmeter/Ammeter Help Displays All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. HE.L P−1 Help 1 Display Indicates a malfunction in the pri- mary power circuit. If this display is shown, contact a Factory Autho- rized Service Agent.

  • Page 40: Error Codes

    6-6. Error Codes Program CRC Error Program Range Error If either error code appears, reset the display to factory settings as fol- lows: Press Parameter Select push but- ton or turn welding power source E R R O R Off and back On. Change settings and continue.
  • Page 41 Notes Return To Table Of Contents OM-193 267 Page 37...

  • Page 42: Section 6 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Welding Power Source (230/460 Volt Models) OM-193 267 Page 38 Return To Table Of Contents...
  • Page 43 193 264-A Return To Table Of Contents OM-193 267 Page 39...
  • Page 44 Figure 6-2. Circuit Diagram For Welding Power Source (575 Volt Models) OM-193 267 Page 40 Return To Table Of Contents...
  • Page 45 206 318-A Return To Table Of Contents OM-193 267 Page 41...

  • Page 46: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 316-B Figure 8-1. Complete Assembly OM-193 267 Page 42 Return To Table Of Contents...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly ....187 234 . . . COVER, top ...........
  • Page 48 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly (Continued) ....153 169 . . . ACTUATOR, switch ..........
  • Page 49 Notes OM-193 267 Page 45 Return To Table Of Contents...
  • Page 50 Notes OM-193 267 Page 46 Return To Table Of Contents...
  • Page 51 Effective January 1, 2002 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions APT, ZIPCUT &...

  • Page 52: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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