Miller Invision 456P User manual

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QM-188 989A
November
1997
Eff.
w/Serial
Number
KH504356
Processes
Invision
456P:
~
MIG
(GMAW)
and Pulsed
MIG
(GMAW-P)
Welding
Flux
Cored
(FCAW)
Welding
Phoenix 456
CC/CV:
Multiprocess
Welding
Description
lnvision 456P:
Phoenix
456
CC/CV:
Invisionfi456P and
Phoenixfi456
CC/C
V
(575
Volt
Models)
OWNERS
MANUAL
The
Thwer
fBkte.

From
Miller
to
You
Thank
you
and
congratulations
on
choosing
Miller.
Now
you
can
get
the
job
done
and
get
it done
right.
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.
Like
you,
his
customers
couldnt
afford
anything
less. Miller
products
had
to
be
more
than
the
best
they
could be.
They
had
to
be the
best
you
could
buy.
Today,
the
people
that
build
and sell Miller
products
continue the
tradition.
Theyre
just
as
committed
to
providing
equipment
and service
that
meets
the
high
standards
of
quality
and value
established
in
1929.
This
Owners Manual is
designed
to
help
you
get
the
most out
of
your
Miller
products.
Please take time
to
read the
Safety precautions. They
will
help
you
protect
yourself
against
potential
hazards
on
the
worksite.
Weve
made
installation
and
operation
quick
and
easy.
With Miller
you
can
count
on
years
of reliable
service
with
proper
maintenance. And if
for
______________
some reason
the unit needs
repair,
theres
a
Troubleshooting
section that will
help
you
figure
out
what the
problem
is.
The
parts
list
will
then
help
you
to
decide which
exact
part
you
may
need
to
fix
the
problem.
Warranty
and
service
information
for
your
particular
model
are
also
provided.
Miller Electric
manufactures
a
full line
of welders and
welding
related
equipment.
For
information
on
other
quality
Miller
products,
contact
your
local Miller
distributor
to
receive
the latest
full line
catalog
or
individual
catalog
sheets.
To
locate
your
nearest
distributor
call
1-800-4-A-Miller.
iIk~iIllhIIJP
IREGISTEREDI
IQUALITY
SYSTEM
Miller is the tirat
welding
equip
mentmanufacturerlntheU.S.A.to
be
registered
to
the ISO
oooi
quality System
Standard.
W~1~ftflfl~
L~
Working
as
hard
as
you
do~
every
power
source
from
Miller
is
backed
by
the
most
hassle-free
warranty
in the
business.
f//A
Miller
Thwer~fBhte~

Call
1
-800-4-A-MILLER
for
your
local
Miller disiributor.
Your
distributor
gives
you
Service
You
always
get
the
fast,
reliable
response you
need.
Most
replacement
parts
can
be
in
your
hands in 24 hours.
Support
Need
fast
answers
to
the
tough
welding questions?
Contact
your
distributor.
The
expertise
of
the
distributor
and
Miller is
there
to
help
you, every
step
of the
way.
Miller
offers
a
Technical
Manual
which
provides
more
detailed service and
parts
in formation
for
your
unit.
To
obtain
a
Technical
ManuaI~
contact
your
local
distributor. Your
distributor
can
also
supply
you
with
Welding
Process Manuals
such
as
SMAW, GTAW,
GMAW,
and
GMAW-P
For
practical
in formation
on
welding,
process
applica
tions,
and Miiler
products,
visit
our
website
at
www.MlllerWelds.com
The
following
terms
are
used
interchangeably
throughout
this
manual:
TIG
= GTAW
Stick
=
SMAW
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
1
1-1.
Symbol Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Additional
Symbols
for
Installation,
Operation,
and
Maintenance
3
1-4.
Principal Safety
Standards
3
1-5.
EMF
Information
4
SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE AVANT UTILISATION
5
1-1.
Signification
des
symboles
5
1-2.
Dangers
relatifs
au
soudage
a larc
5
1-3.
Dangers
supplØmentaires
en
relation
avec
Iinstallation,
le
fonctionnement
et
Ia
maintenance
7
1-4.
Principales
normes
de
sØcuritÆ 8
1-5.
Information
sur
les
champs
electromagnetiques
8
SECTION
2-
INSTALLATION
9
2-1.
Specifications
9
2-2.
Duty
Cycle
and
Overheating
9
2-3.
Volt-Ampere
Curves
10
2-4.
Dimensions
And
Weight
11
2-5.
Selecting
a
Location
11
2-6.
Weld
Output
Terminals and
Selecting
Cable
Sizes
12
2-7.
Remote
14
Receptacle
Information
12
2-8. 115 Volts
AC
Duplex
Receptacle
And
Circuit Breakers
13
2-9.
Electrical Service Guide
13
2-10.
Connecting
Input
Power
14
SECTION 3-OPERATION
15
3-1.
Front
Panel Controls For
Invision 456P
15
3-2.
Mode
and
Voltage
Control
For
Invision
456P
15
3-3.
Meter Functions For Invision 456P 16
3-4.
Front
Panel
Controls
For
Phoenix
456
CC/CV
16
3-5. Meter
Functions
For
Phoenix
456
CC/CV
17
3-6.
Mode
Switch
Settings
For
Phoenix
456
CC/CV
17
3-7.
Lift-Arc TIG
Procedure For
Phoenix
456
CC/CV
18
SECTION
4-
MAINTENANCE
AND
TROUBLESHOOTING
16
4-1.
Routine Maintenance
18
4-2.
Blowing
Out
Inside of Unit
19
4-3.
Removing
Case
and
Measuring
Input
Capacitor
Voltage
20
4-4.
Voltmeter/Ammeter
Help
Displays
21
4-5.
Troubleshooting
22
SECTION
5-
ELECTRICAL DIAGRAF~t
24
SECTION
6-
PARTS
LIST
26
WAR RANTY
OM-186
989

SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
_nd_5/97
This
group
of
symbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS hazards.
Consult
symbols
and related
instructions
below
for
necessary
actions
to
avoid the hazards.
A
The
symbols
shown below
are
used
throughout
thIs
manual
to
call
attention
to
and
Identify possible
hazards. When
you
see
the
symbol,
watch
out,
and foliowthe
related Instructions
to
avoid the hazard. The
safety
Information
given
below
Is
only
a
summary
of the
more
complete safety
Information
found In the
Safety
Standards listed In
Section
1-4. Read
and
follow all
Safety
Standards.
A
Only qualified
persons
should
Install,
operate,
maintain,
and
repair
this unit.
A
During operation,
keep everybody, especially
children,
away.
=t~L~~
cton.
~
\
Touching
live electrical
parts
can cause
fatal
shocks
or
severe
burns.
The
electrode
and work
circuit is
electrically
live whenever the
output
is
on.
The
input
power
circuit and machine internal
circuits
are
also live when
power
is
on.
In semiautomatic
or
automatic wire
welding,
the
wire,
wire
reel,
drive roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded equipment
is
a
hazard.

Do
not
touch live electrical
parts.

Wear
dry,
hole-free
insulating gloves
and
body protection.

Insulate
yourself
from
work and
ground using
dry
insulating
mats
or covers
big enough
to
prevent
any
physical
contact
with the
work
or
ground.

Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there is
a
danger
of
falling.

Use AC
output
ONLY
if
required
for
the
welding
process.

If AC
output
is
required,
use
remote
output
control
if
present
on
unit.

Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment. Lockout/tagout
input
power
according
to
OSHA29
CFR
1910.147
(see
Safety
Standards).

Properly
install and
ground
this
equipment
according
to
its
Owners Manual
and
national,
state,
and local
codes.

Always verify
the
supply ground

check and be
sure
that
input
power
cord
ground
wire is
properly
connected
to
ground
terminal
in disconnect box
or
that cord
plug
is connected
to
a
properly
grounded
receptacle
outlet.

When
making input
connections,
attach
proper
grounding
conductor
first

double-check
connections.

Frequently inspect input
power
cord for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.

Turn off all
equipment
when
not
in
use.

Do
not
use
worn,
damaged,
undersized,
or
poorly spliced
cables.

Do
not
drape
cables
over
your
body.

If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work
cable.

Do
not
touch electrode if
you
are
in
contact with
the
work,
ground,
or
another
electrode
from
a
different machine.

Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
Maintain unit
according
to
manual.

Wear
a
safety
harness
if
working
above floor level.

Keep
all
panels
and
covers
securely
in
place.

Clamp
work cable with good
metal-to-metal
contact to
workpiece
or
worktable
as near
the weld
as
practical.

Insulate work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.

Do
not connect
more
than
one
electrode
or
work cable
to
any
single
weld
output
terminal.
SIGNIFICANT
DC VOLTAGE
exists
after
removal of
input
power
on
inverters.

Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions in
Maintenance
Section
before
touching
any
parts.
I
Welding
produces
fumes
and
gases.
Breathing
I I
these fumes
and
gases
can
be
hazardous
to
your
health.

Keep
your
head
out
of
the
fumes.
Do
not
breathe
the fumes.

If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.

If
ventilation is
poor,
use an
approved
air-supplied respirator.

Read the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers instructions for
metals,
consumables,
coatings,
cleaners,
and
degreasers.

Work
in
a
confined
space
only
if it
is well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watch-
person
nearby. Welding
fumes
and
gases
can
displace
air and
lower
the
oxygen
level
causing injury
or
death.
Be
sure
the
breathing
air is
safe.

Do
not
weld in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The heat
and
rays
of
the
arc can
react
with
vapors
to
form
highly
toxic and
irritating
gases.

Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these elements
can
give
off
toxic fumes if
welded.
I I
Cti~ik iii T~1

~,,y
.~o1
~sa~,e
~
~
~.
~
~
~.
.*...
4~
Means
Warning!
Watch
Out!
There
are
possible
hazards with this
procedure!
The
possible
hazards
are
shown in the
adjoining symbols.
A
Marks
a
special
safety
message.
~
Means
Note~
not
safety
related.
Hazard
~
...
~
__________N
OM-186
989
Page
1