Miller Maxtron 450 User manual

Millerfi
July
L__Effe
1996
ctive
With
Form:
Serial
No.
OM-167302C
KG181431
OWNERS
MANUAL
MaxtronTM
450
-
CE
CCICV
DC
Welding
Power Source For
GMAW,
GTAW, SMAW,
FCAW,
CAC-A, GMAW-P,
GTAW-P,
And SAW
Welding
Rated
Welding
Output
Voltage
Range
In
CV
Mode
Amperage
Range
In
CC
Mode
Maximum
Open-
Circuit
Voltage
DC
i~
Rating
Amperes
Input
at
Rated Load
Output
50
Hz,
Three-Phase
380
V
I
415
V
38 35
(08)
I
(0.7)
I
KVA
I
KW
400 A
'
34
Volts
DC,
100%
Duty
Cycle
1238 V
5565
A
80
VDC
21
25 25
(0.5)*
(0.2)
*While
idling
cover_om
4/95

ST-BOO
763-A
'
1996
MILLER EIe~tric
Mfg.
Co.
PRINTED
IN
USA

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I
LIMITED
WARRANTY

Subject
to
the
terms
snd
conditions
below,
MILLER
Electric
Mtg.
Co.,
Appleton,
Wisconsin,
wsrrsnts
to
its
original
retail
purchaser
thst
new
MILLER
equipment
sold
sher
the effective
date
ot
this limited
wsrrenty
is tree ot
de
tects in
material
snd
workmanship
st
the
time
it
is
shipped
by
MILLER.
THtS WAR
RANTY
IS
EXPRESSLY
tN LIEU OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLtED,
INCLUDtNG
THE
WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
Within
the
wsrranty
periods
listed
below,
MILLER
will
repait
or
reptsce
sny
war-
rented
parts
or
components
thst tell
due
to
such
detects
in
material
or
workmanship.
MILLER
tnust
be
notified in
writing
within
thirty
(30)
days
of
such
detect
or
failure,
et
which time
MtLLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
tollowed.
MILLER shell
honor
warranty
claims
on
werrented
equipment
listed below in
the
event
ot such
e
failure within
the
warranty
time
periods.
All
warranty
time
periods
stert
on
the
dete
thet
the
equipment
wee
delivered
to
the
original
retell
purcheser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent to
an
International
distributor.
1. 5
Years Parts 3 Years Labor
*
Original
main
power
rectifiers
*
tnverters
(input
and
output
rectifiers
only)
2.
3 Years

Parts and
Labor

Transformer/Rectitier
Power
Sources
*
Plasma
Arc
Cuning
Power
Sources

Semi-Automatic
and Automatic Wire
Feeders
*
tnverter
Power
Supplies

tntellitig

Robots
3. 2
Years
Parts
and Labor

Engine
Driven
Welding
Generators
(NOTE: Engines
are
warranted
separately by
the
engine manutacturer.)
*
Air
Compressors
4. 1
Year

Parts
and Labor
Motor
Driven
Guns
*
Process
Controllers

IHPS
Power Sources
*
Water
Coolant
Systems
*
HF
Units
*
Grids

Spot
Welders
*
Load
Banks
*
SDX
Transformers

Running
Gear/Trailers

Plasma
Cuffing
Torches
(escept
APT,
ZIPCUT
&
PLAZCUT
Models)

Tecumseh
Engines
*
Deutz
Engines (outside
North
America)

Field
Options
(NOTE:
Field
options
are
covered under
True Bluefi
for
the
remaining
warranty
period
of the
product they
are
installed
in,
or
for
a
minimum of
one
year

whichever is
greater.)
 I
~Wt
5. 6
Months

Bafteriea
6.
go
Days

Parts
and Labor
*
MtG
Guns/TIG Torches
APT,
ZIPCUT
&
PLAZCUT
Model Plasma
Curling
Torches

Remote
Controls
*
Accessory
Kits
Replacement
Parts
MILLERS
True
Bluefi Limited
Warranty
shall
not
apply
to:
1. Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips, cusing
nozzles,
contaclors
and
relays
or
parts
that tail due
to
normal
wear.
3.
Equipment
that
has
been modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has been
used
for
operation
outside
of
the
specifications
for the
equipment.
MILLER
PRODUCTSARE
INTENDED
FOR PURCHASE AND USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE OF WELDING EOUIPMENT.
In
the
event
of
a
warranty
claim covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option: (1) repair;
or
(2)
replacement;
or,
where authorized in
writing
by
MILLER
inappropriate
cases,
(3)
the reasonable
coat
of
repair
or
replace
ment at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit for the
pur
chase
price (leas
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
espenae.
MILLERS
option
of
repair
or
replacement
will be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER authorized
ser
vice
facility
as
determined
by
MILLER.
Theretore
no
compensation
or
reimburse
ment
for
transportation
coats
of
any
kind
will
be allowed.
TO THE EXTENT
PERMITTED BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE THE
SOLE
AND EXCLUSIVE
REMEDIES.
IN
NO EVEHT
SHALL
MILLER BE
LIABLE FOR
DIRECT, INDIRECT,
SPECIAL,
INCIDENTAL
OR CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON CON
TRACt
TORT
OR
ANY
OTHER
LEGAL THEORY.
ANY
EXPRESS
WARRANTY
NOT PROVIDED
HEREIN
AND
ANY IMPLIED WAR
RANTY,
GUARANTY OR REPRESENTATION
AS TO
PERFORMANCE,
AND ANY
REMEDY
FOR
BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL
THEORY
WHICH,
BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM OF
TRADE OR
COURSE
OF
DEALING,
IN
CLUDING
ANY IMPUED WARRANTY OF
MERCHANTABILITY OR FITNESS
FOR PARTICULAR
PURPOSE,
WITH
RESPECT TO
ANY
AND ALL
EOUIPMENT
FURNISHED BY
MILLER
IS EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations of
how
tong
an
implied
warranty
lasts,
or
the
esclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal rights,
and other
rights
may
be
available,
but
may vary
from
state to
state.
In
Canada,
legislation
in
some
provinces provides
for
certain
additional
warranties
or
remedies other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and exclusions
set out
above
may
not
apply.
This
Limited
Warranty provides
specific
legal rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
WHO DO
I
CONTACT?
For
help,

contact
your
distributor
For
additional
information,
such
as
Technical
Manuals
(SerVice
And
Parts)
Engine
Manuals
Circuit
And
Wiring Diagrams
Process
Handbooks
To
file
a
claim for
loss
or
damage
during
shipment,
.
contact
the
deliVering
carrier
For
assistance in
filing
or
settling
claims,
.
contact
your
distributor and/or
equipment
manufacturers
Transportation
Department
~j~3jjj5~
1211]
Miller
Electric
Mfg.
Co.

CALL:
414-735-4505

FAX:
800-637-2348
(in USA),
or
414-735-4136
(outside
USA)
Users Guides
Distr(butor Directories

contact
your
distributor
oi
.
WRITE:
Miller Electric
Mfg.
Co.
P.O.
BOX 1079
Appleton,
WI
54912
USA
Always provide
Model
Name and
Serial
or
Style
Number
MILLERS
TRUE
BLUEfi LIMITED WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
i-u
miller...wsrl
6/g5

Declaration of
Conformity
For
EurOpean
Community
(CE)
Products
Manufacturers Name:
Miller Electric
Mfg.
Co.
Manufacturers Address:
1635 W.
Spencer
Street
Appleton,
WI
54914
USA
Declares that
the
product:
M
axtro
flTM
450
conforms
to
the
following
Directives
and
Standards:
Directives
Electromagnetic compatibility
Directives:
89/336/EEC,
92/31/EEC
Low
Voltage
Directive:
73/23/EEC
Machinery
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Standards
Electromagnetic compatibility
(EMC)
Product standard for
arc
welding equipment:
EN50199:
August
1995
Safety Requirements
for
Arc
Welding Equipment
part
1:
EN
60974-1: 1989
Degrees
of
Protection
provided by
Enclosures
(lP code):
IEC
529: 1989
Insulation coordination
for
equipment
within
low-voltage
systems:
Part
1:
Principles, requirements
and
tests:
lEG
664-1:
1992
European
Contact: Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via Privata
lseo
20098
San
Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39(02)98281-552
dec_coni
10/95

SECTION
1
-
SAFETY
PRECAIJTIONS
FOR ARC
WELDING
0M167
302C

7/96
safety_somi
4/95
1-1.
Symbol
Usage
Means
Warning!
Watch
Out! There
are
possible
hazards
with this
A
Marks
a
special
safety
message.
~
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
,
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.
1-2.
Arc
Welding
Hazards
a
WARNING
The
symbols
shown below
are
used
throughout
this
manuai
to
call
attention
to
and
identify
possible
hazards. When
you
see
the
symbol,
watch
out,
and
follow
the related
instructions
to
avoid the hazard.
The
safety
information
given
below
is
only
a
summary
of I:he
more
complete safety
information found
in the
Safety
Standards listed
in
Section
1-4. Read and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintalin,
and
repair
this unit.
During operation, keep everybody,
especially children,
away.
1.
Do
not
touch
live electrical
parts.
2.
Wear
dry,
hole-free
insulating gloves
and
body
protection.
3. Insulate
yourself
from work and
ground using dry insulating
mats
or covers
big enough
to
prevent
any
physical
contact
with
the work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191 0.147
(see Safety Standards).
5.
Properly
install and
ground
this
equipment
according
to
its
Owners Manual and
national,
state,
and local codes.
6.
Always verify
the
supply ground

check and be
sure
that
input
oower
cord around
wire is orooerlv connected
to
around
terminal
in
disconnect box
or
that cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first

double-check connections.
B.
Frequently inspect input
power
cord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work
cable.
13. Do
not
touch electrode
it
you
are
in
contact
with
the
work,
ground,
or
another electrode from
a
different machine.
14.
Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
Maintain unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work cable with
good
metal-to-metal
contact to
workoiece
or
worktable
as
near
the
weld
as
Dractical.
ELECTRIC SHOCK
can
kill.
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.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG OR SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet fitted with
a
proper
shade of filter
to
protect
your
face and
eyes
when
welding orwatching
(see
ANSI
Arc
rays
from the
welding
process
produce
intense
Z49.1
and Z87.1 listed in
Safety
Standards).
visible and invisible
(ultraviolet
and
infrared)
rays
3.
Wear
approved safety glasses
with side shields.
that
can
burn
eyes
and skin. Noise
from
some
processes
can
damage
hearing. Chipping,
4.
Use
protective
screens or
barriers
to
protect
others from flash
grinding,
and welds
cooling
throw
off
pieces
of
and
glare;
warn
others
not to
watch the
arc.
metal
or
slag.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or ear
muffs
if
noise level is
high.
material
(wool
and
leather)
and
foot
protection.
I
FUMES AND
GASES
can
be
5.
Work in
a
confined
space
only
if
it is well
ventilated,
or
while
hazardous
to
your
health.
wearing
an
air-supplied respirator.
Always
have
a
trained
Welding
produces
fumes
and
gases.
Breathing
watchpersonnearby.Weldingfumesandgasescandisplaceair
~
v . these
fumes
and
gases
can
be
hazardous
to
your
and lower the
oxygen
level
causing injury
or
death. Be
sure
the
health.
breathing
air
is
safe.
I
6.
Do
not
weld
in
locations
near
degreasing, cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes. Do
not
breathe
the fumes,
operations.
The heat and
rays
of
the
arc can
react
with
vapors
to
form
highly
toxic and
irritating
gases.
2.
If
inside,
ventilate the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use an
approved
air-supplied respirator.
cadmium
plated
steel,
unless the
coating
is
removed
from
the
4.
Read the
Material
Safety
Data Sheets
(MSDS5)
and the
weld
area,
the
area
is well
ventilated,
and
if
necessary,
while
manufacturers instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers. containing
these elements
can
give
off toxic fumes if
welded.
OM-167
302
Page
1

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